STUDENT INDUSTRIAL TRAINING REPORT

MAY 2015 AUGUST 2015

HOST COMPANY : HAMMER ENGINEERING SDN BHD (HESB)

STUDENT NAME : ANDERSON JOSEPH
MATRIC ID : 16740
PROGRAMME : CHEMICAL ENGINEERING

Acknowledgement

First and foremost, I would like to express my gratitude to Center of Student

Internship, Mobility and Adjunct Lectureship (CSIMAL) for giving me an opportunity to
undergo a 14 weeks internship program in Hammer Engineering Sdn Bhd located in Shah
Alam, Selangor. CSIMAL has done an excellent job by mapping out an elaborate internship
program with specified objectives and outcomes besides assigning supervisors to us and
carrying out meetings to cater students problem regarding internship program. Hereby, I
would like to thank my UTP supervisor, Dr. Asna bt Mohd Zain who was willing to come all
the way to Hammer Engineering to evaluate my presentation and guided me all this while
when there is any issue in my internship period.

Furthermore, I am also grateful for my department manager Mr. Eh San for his
valuable support, guidance and encouragement during my internship training. Without his
guidance, I would not be able to learn a lot and gain knowledge as much as I can. In addition,
there are also other people that helped me a lot throughout the learning process in Hammer
Engineering. I would like to express my immense gratitude to Mr. Hafizzudin, Assistant
Fabrications Manager who taught me the technical jargons and performance and quality
monitoring system which has been used within the company. Also to Mr. Azahari, Head of
Service Department, who had sent me to site visits together with the service team.

I also would like to thank all the staffs of Fabrication and Construction services
department, for sharing their expertise and assistance which provides me with wonderful
experience. Last but not least, I would like to give acknowledgement to all parties who had
also contributed directly and indirectly to the success of my Industrial Internship Program.

Thank You.

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TABLE OF CONTENTS
HOST COMPANYS VERIFICATION STATEMENT
ACKNOWLEDGEMENTS
TABLE OF CONTENTS
LIST OF FIGURES
LIST OF TABLES
1.0 INTRODUCTION
1.1 OBJECTIVE OF INDUSTRIAL TRAINING
1.2 HOST COMPANY BACKGROUND
1.3 ORGANIZATION MISSION AND VISION
2.0 GENERAL OVERVIEW OF THE COMPANY
2.1 CORE BUSINESS
2.2 TYPE OF PRODUCTS
2.3 TYPE OF SERVICES
3.0 WORK CULTURE
3.1 OCCUPATIONAL HEALTH AND SAFETY
3.11 SAFETY REGULATIONS
3.12 TRAINING PROVIDED
3.13 COMPANY SOP
3.2 WORK ENVIRONMENT
3.21 TEAM WORK
3.22 WORK ETHICS
4.0 WORK EXPERIENCE
4.1 SKILLS GAINED
4.2 KNOWLEDGE
5.0 DISCUSSION ON SUSTAINABILITY
5.1 COMMON PRACTICE AND FUTURE RECOMMENDATIONS
6.0 CONCLUSIONS AND RECOMMENDATIONS
7.0 REFERENCES
8.0 GLOSSARY

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PAGE
LIST OF FIGURES

NO.

Figure 1 Hammer Engineering at OGA 2015

Figure 2 Pre-commissioning check on station

Figure 3 Project Team working on-site

Figure 4 PCV TRANSDUCER INSTALLATION AT PGB YTL PAKA

METERING STATION
Figure 5 F500 Metering and Regulating Station

11

Figure 5 D500 Metering and R

12

Figure 6 F2000 Metering and Regulating Station (under construction)

13

Figure 7 : F4000 Metering and Regulating Station

14

Figure 8:F6000 Metering and Regulating Station

15

Figure 9:Daggaz Odorizer System (Industrial Type)

16

Figure 10 Nirmal GAS PRESSURE REGULATOR - D53-R3

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Figure 11 BYHO Valves Floating Mounted Ball Valve

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Figure 12 Site Installation of Station

20

Figure 13 Electrical and Instrumentation Works

21

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LIST OF TABLES

PAGE NO

Table 1 BYHO Floating Ball Valve specifications

18

Table 2 OHSE MS CLAUSES

23

Table 3 Design Pressure & Test Pressure

27

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1. INTRODUCTION

University Technology PETRONAS (UTP) has made it clear of its objective of producing
well-rounded graduates since its establishment on the 10th of January 1997 by introducing a
very different set of Student Industrial Internship Program (SIIP) that enables students to not
only be competent in technical skills but attain lifetime learning capacity, critical thinking,
grooming skills and practical amplitude.

SIIP at UTP is carried out for 28 weeks unlike most universities that only train for a
duration of 14 weeks. UTP has divided its SIIP into two phases, the first phase which will be
conducted for 14 weeks comprise of Student Internship Training (SIT) and the next 14 weeks
will be Student Internship Project (SIP).

Centre of Student Internship, Mobility, and Adjunct Lectureship is an organization that

handles all work regarding students internship program from finding placement to handling
important paper works that enables us to conduct our internship with ease. During the preinternship period, students need to compete among themselves to get a placement in a
company that will put their knowledge to the test when it comes to practical skills.

Students are required to put forth their best resume and academic transcripts to draw
the companys attention. However, Cumulative Grade Point Average (CGPA) is not the only
factor that will confirm the student of their placement. Extra curriculum activities and
personality is also taken into account by a company before recruiting. Therefore, students
have to show their resume in detail but yet never forgetting the key factors on what
companies look for in a student in order to be selected for their industrial training.

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1.1 Objective

The main objective of industrial internship is to expose UTP students to the real working
environment in order to relate theoretical knowledge with application in industry. Through
the industrial training, students will be able to partake in activities to develop skills in work
ethics, communication, safety practices, management, etc. Apart from that, the industrial
training also helps to establish a close relationship between the industry and UTP.
At the end of the industrial training, all students must incorporate the knowledge gained at
their host company to meet the objectives of the SIIP which is as follows:-

1. To practice theories learned and relate it to actual working field.

2. To introduce students to work culture and industrial practices.

3. To enhance the creativity capacity and contribute professionally to the host company

4. To increase students awareness on the function and the importance of implementing

Health, Safety and Environment practices at workplace.

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1.2 Host Company Background

Figure 1 Hammer Engineering at OGA 2015

Hammer Engineering Sdn Bhd (HESB) is fairly new player in the oil and gas industry.
Since its inception in 2008, HESB has grown significantly to become the preferred name in
downstream LNG arena. Devoting their talent to project management and engineering, HESB
has performed beyond expectation to obtain licences from local authorities and oil and gas
industry leaders within one year of its incorporation.

At present, HESB is operating in Seksyen 32 , Shah Alam with a fabrication yard

and a testing facility within 1 km radius from the administration office. HESB has a truly
humble beginning when it began operating in 2008 with a handful of staffs, all fabricating
and testing activities where done in the ground floor of the administration building itself.
Like an avalanche that rose from a snowball, HESBs reputation in the industry and project
acquisition grew simultaneously at an exponential rate, all thanks to the tireless effort of the
entire team of staffs at that time.
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Grinding through the years, HESB has developed expertise in EPCC of skid packages
and project management, with total commitment to quality and excellence. HESB has long
standing experience in EPCC of custody transfer stations, metering stations and regulating
stations for downstream LNG distribution network.

HESB is also reputed for their Electrical and Instrumentation services in the industry
and has often been a winner of such projects. Currently, HESB has the benefit of being Gas
Malaysia Berhads primary contractor for construction of metering and regulating stations
and has enormous experience executing their projects all over the country.

1.3 Organisation Mission and Vision

Vision

To be a leading world class solution provider in the oil and gas industry.

Mission

To provide our clients with a world class products and services that is based on a corporate
culture driven by customers focus, impeccable ethics, total commitment to quality, timely job
completion, and uncompromising protection to health, safety and the environment.
To provide our employees with adequate rewards, remuneration and training to empower and
motivate them to be a world classwork forces that pushes the boundaries of our core
competencies.
To provide our vendors with win-win long term business relationship that is based on the
spirit of collaboration, mutual trust, and integrity.
To provide our shareholders with the maximization of profits and best operating processes.
To be a responsible and caring corporate citizen that serve the best interest of our community,
and actively support our Nation's aspirations.

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2. General Overview of the Company

Figure 2 Pre-comissioning check on station

Hammer Engineering is a project engineering company with specific forte on

downstream LNG industry. Shah Alam being one of the industrial powerhouses of Selangor
would be an ideal place to be since most industrial areas such as Klang, Pulau Indah, and the
likes of it are within commutable distance. The reason why the aforementioned reach is
important is because most companies which uses steam turbine for electricity generation will
use LNG as fuel to heat up the boiler. This is not limited to just factories. Fuel stations,
commercial complexes, residential area, and city gate custody transfer stations are some of
the project sites I have witnessed during my training in here.

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So where does Hammer Engineering plays the role in this field? Ideally, Hammer
Engineering would come into picture when the gas supplying company requires a contractor
to manage the EPCC of the Gas Regulating and Metering stations for the particular purpose.
Then onwards, Hammer Engineering holds full responsibility from sizing of the equipment to
product realization, when the station is constructed, the project team performs commissioning
and undertakes Final Acceptance Test and Site Acceptance Test to ensure product
functionality.

Our job does not end there. Regular servicing and provision of maintenance material
shall be pursued until the stated date in the contract. This is just a brief description of an
elaborately complex process that is requires more than just theoretical knowledge to witness
and understand.

Figure 3 Project Team working on-site

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2.1 Core Businesses

Hammer Engineerings is a feared contender in the field of EPCC (Engineering,

Procurement, Construction and Commissioning) project management. Hammer Engineering
has partaken projects of such nature since its establishment and have grown vastly
experienced in this niche.

The breakdown of our core business can be observed as follows;

Engineering Functions

Initiation

Implementation

Planning & Programming

Estimating Request for Quote

Valuation

Sizing and Selection

Procurement Functions

Purchasing

Expediting

Receiving

Invoicing

Reconciliation

Construction Functions

Construction Schedule

On-site Material Handling

Construction Activities

On-site Client Communications

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Valuation & Cash flow

testing & checking

Commissioning and Hand-over

In light to our expertise, it would be my pleasure to present to you the vast potential of
Hammer Engineering in a wide array of fields. Hammer Engineering is passionate about the
quality, health, safety and environment of our work at all times and we strive to meet other
requirements to serve the personnel and clients in the following areas:

EPCC of Custody Transfer Metering and Regulating Stations

EPCC of Gas Odorizer System

Electrical and Instrumentation Works

Vendor for Oil and Gas Equipments

Project Management

API Valve Testing

Figure 4 PCV TRANSDUCER INSTALLATION AT PGB YTL PAKA METERING STATION

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2.2 Types of Product

Hammer Engineering provides a multitude of products and services to its clients as stated in
the overview. I will now detail in on each service for better clarity of Hammer Engineerings
role in this industry.

EPCC of Custody Transfer Metering and Regulating Stations

Before I explain further on the types of stations, let me define the technical jargon that
precedes these stations. Custody Transfer in the oil and gas industry refers to the transactions
involving transporting physical substance from one operator to another. This includes the
transferring of raw and refined LNG between one operator to another. Custody transfer in
fluid measurement is defined as a metering point (location) where the fluid is being measured
for sale from one party to another.

The Metering and/or Regulating Stations functions to reduce and regulate the
downstream pressure, measure the quantity of energy transferred from the natural gas
transmission system to the medium pressure networks or to consumers connected directly to
the transmission system and add a distinctive odour to the natural gas for prompt detection of
any gas leakage (when required by the national safety regulations).

For this reason the Metering and/or Regulating Stations fabricated by Hammer Engineering
are equipped with:

Regulating valves which measure and regulate continuously the operating pressure of
the gas in distribution networks;

Slam shut valves for protection of the downstream systems from any violation of the
operating pressure limits (for example, after failure of the regulating valve);

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Modern metering systems with Electronic Volume Corrector(EVC) for the continuous
measurement of the quantity and the quality of the supplied natural gas;

Pressure Relief Valve to control or limit the pressure in the station which can build up
and cause process failure, instrument or equipment failure, or fire. The pressure is
relieved by allowing the pressurised fluid to flow from an auxiliary passage out of the
system.; and

Odoriser systems to add the distinctive odour for an early detection of gas leakage.

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The types of stations and its specifications are as followed;

F500 Metering and Regulating Station

Figure 5 F500 Metering and Regulating Station

INLET OPERATING PRESSURE: 1034 kPa / 2483 kPa

OUTLET OPERATING PRESSURE: 1800 kPa
FLOWRATE: 21 m3/hr. (MIN), 500 m3/hr. MAX
TEST PRESSURE (ANSI 150#): 2483 X 1.5 = 3725 kPa

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D500 Metering and Regulating Station

Figure 6 D500 Metering and Regulating Station

INLET OPERATING PRESSURE: 241 kPa / 400 kPa

OUTLET OPERATING PRESSURE: 140 kPa
FLOWRATE: 36 m3/hr. (MIN), 500 m3/hr. MAX
TEST PRESSURE (ANSI 150#): 400 X 1.5 = 600 kPa

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F2000 Metering and Regulating Station

Figure 7 F2000 Metering and Regulating Station (under construction)

Used for industrial stations and small to medium commercial businesses. F indicates feeder
line.
INLET OPERATING PRESSURE: 1034 kPa / 2483 kPa
OUTLET OPERATING PRESSURE: 140 kPa
FLOWRATE: 118 m3/hr. (MIN), 2200 m3/hr. MAX
TEST PRESSURE (ANSI 150#): 2483 X 1.5 = 3725 kPa

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F4000 Metering and Regulating Station

Figure 8: F4000 Metering and Regulating Station

Used for industrial stations. F indicates feeder line. Also used in city gate stations.
INLET OPERATING PRESSURE: 1034 kPa / 2483 kPa
OUTLET OPERATING PRESSURE: 1800 kPa
FLOWRATE: 400 m3/hr. (MIN), 4000 m3/hr. MAX
TEST PRESSURE (ANSI 150#): 2483 X 1.5 = 3725 kPa

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F6000 Metering and Regulating Station

Figure 9:F6000 Metering and Regulating Station

Mainly used for large industrial stations with high volume of feed requirement. Also used in
city gate stations.
INLET OPERATING PRESSURE: 1034 kPa / 2483 kPa
OUTLET OPERATING PRESSURE: 1800 kPa
FLOWRATE: 555 m3/hr. (MIN), 6000 m3/hr. MAX
TEST PRESSURE (ANSI 150#): 2483 X 1.5 = 3725 kPa

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Daggaz Odorizer System

Figure 10:Daggaz Odorizer System (Industrial Type)

Hammer Engineering is the authorised vendor for Turkey-made Daggaz Odorizers in

Malaysia.
The characteristics of Daggaz Odorizer System (Industrial Type)
Manual and automatic control of injection pumps.
By the help of the info of gas odorant flow rate gotten from flow meter in the pump
cabinet, system can arrange itself automatically according to newly calculated period.
According to the flow rate of natural gas in the pipeline, the system will arrange the gas
odorant rate then will inject gas odorant into pipe line.
For service and maintenance, the system can work in manual mode.
Atex certified and CE signed pneumatic panel
IP 66 Certified pneumatic panel
For hazardous areas, it is recommended to install controller panel to operator room (for
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economical purposes) while installing atex pneumatic panel in hazardous areas.

D-Series Pressure Regulators by Nirmal Industries

Hammer Engineering is the authorised vendor for D-Series Pressure Regulators made by
Nirmal Industries (India).

GAS PRESSURE REGULATOR - D53 /- Series

SERIES D53 REGULATOR WITH BUILT-IN SLAM

SHUT DEVICE
SERIES D53 pressure regulator offers the possibility of
installing an incorporated slam shut off device whenever it is
functioning either as a main or as a monitor regulator.
The incorporated slams shut off device can be retrofitted to
SERIES D53 regulator without modifying the pressure
reduction assembly. Thus all the specifications are same as
that of SERIES D53 regulator.
SLAM SHUT OFF
This device cuts off the gas flow if any failure causes the

Figure 11 Nirmal GAS PRESSURE

REGULATOR - D53-R3

downstream pressure to rise and reach the set point of the slam shut itself. The slam shut off
device can be re-set manually.
Features:
Tight Shut off Capability
Special trim design eliminates wear and erosion of seating, providing excellent tight shut off
capability over long working life.

Active Monitor Configuration Suitability

This model is suitable for use as Active - Monitor Configuration.
Double Stage Pilot control
Because of double stage pilot design, these regulators can handle high variations in inlet
pressure without affecting the accuracy of outlet controlled pressure.
Easy to Maintain
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Sturdy and compact design with minimum number of moving parts. Actuator internals, Valve
disc & trim parts can be replaced without removing the regulator from pipe line.
Built in Slam Shut Off Option available
Built-in Slam Shut Off (with OPSO & UPSO) can be provided as an optional feature. SSV
can be provided with local position indicators & Limit switches for remote feedback.
PE D/97/23/EC Compliance
SERIES D53 regulators have PED/97/23/EC compliance certification and also conform to
EN 334 requirements.

Specifications
Body Size & Connections Flanged :
1", 2", 3", 4", 6" & 8" ANSI B16.5 Class 150# & 300# (Higher sizes & ratings on request)
Accuracy Class AC :
up to 1.0 (according to EN-334)
Closing pressure Class SG :
up to 2.5
Max. Inlet Pressure Pressure :
19 Barg for Flanged ANSI B16.5, 150# rating and 48 Barg for Flanged ANSI B16.5, 300#
rating Temperature Capabilities :
20C to 60C (extended temperature ranges available on request)
Pressure Setting Adjustment :
May be adjusted throughout a spring range by turning the adjusting screw of pilot.
Pressure Registration :
External 3/8" NPTF, from upstream & downstream main line.

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Ball Valves from BYHO Valves Co.Ltd

Hammer Engineering is the authorised vendor for Ball valves from BYHO Valves Co Ltd
from Zhejiang province, China.

Figure 12 BYHO Valves Floating Ball Valve

Size Range:

NPS 2"56"

Pressure Range:

Class 1502500

Material Range:

WCB, LCB, CF8, CF8M, CF3, CF3M, A105, LF2, F304, F316

Basic Design:

API 608, API 6D, BS 5351, ASME B16.34

Face to Face Dimension:

ASME B16.10, API 6D

Inspection & Testing:

ISO 5208, API 6D

Flanged End Dimension:

ASME B16.5, ASME B16.47, ASME B16.25

Fire Durable:

API 607

Anti-static:

API 608
Table 1BYHO Floating Ball Valve specifications

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2.3 Types of Services

Hammer Engineering commits to serve the industry in the following disciplines:

Figure 13 Site Installation of Station

EPCC of Custody Transfer Metering and Regulating Stations

Right from project kick off, until hand over of documents to client, Hammer Engineering
devotes dedication and quality whilst complying to regulations and safety standards. Below
are the typical process flow of EPCC of Custody Transfer Metering and Regulating Stations;

Project Execution - Project Award and Kick-off Meeting

Preliminaries Insurance and Bank Guarantee
Engineering Calculations, Specification, Drawings, Regulatory body approval (PTI,PTO)
Procurement Purchase of Materials
Construction Fit-up, NDT, HT, Blasting and Painting, Hook-up
Commissioning- FAT, SAT, Commissioning

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Figure 14 Electrical and Instrumentation Works

Electrical and Instrumentation Works

1. Power Consumption
2. Cable Sizing
3. Technical Datasheet
4. DB Sizing, UPS & Battery Sizing
5. System Design - Development & Configuration of Programmable Logic Controller (PLC)
and Man Machine Interface (MMI)

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3.0 Work culture

3.1 Occupational Safety and Health

3.11 Safety Regulations

Safety is a very important aspect in any company. As a company that fabricates metal
products, operators are obliged to use many machineries. Thus, enforcement of safety
regulations are strict and clear in the company. Despite of the size of the company, Hammer
Engineering really do take serious attention in safety practices and policy establishment. The
Occupational Health, Safety and Environment department has four expected outcomes which
are:

1. To achieve 100% staff awareness on OHSE

2. To achieve zero accident
3. To preserve Environment
4. Complying with OHSE Legal and other requirements

Hammer Engineering has an established, documented and implemented OHSEMS

(Occupational Health, Safety, and Environmental Management System), which the
organization has committed to maintain and continuously improve.

The OHSE MS shall fulfil the requirements of MS 1722 : 2005, OHSAS 18001 : 2007 and
ISO 14001 : 2004 national and international standards, and applicable to all activities of
Hammer Engineering that shall affect Health and Safety of employees and workers as well
as the interaction of environment. The establishment of HESB OHSE MS is based on the
Plan-Do-Check-Act (PDCA) Model, which embodies the concept of continual improvement.

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The linkage of elements in HESB OHSE MS is as follows:-

PDCA CYCLE

OHSE MS CLAUSES

Plan OHSE Policy

Hazard Identification, Risk Assessment, and Determining Control
Environmental Impact Assessment
Legal and Other Requirements
OHSE Objectives, Targets and Programs

Do Implementation and Operation

Resources, Roles, Responsibility and Authority
Training, Awareness and Competency
Consultation and Communication
OHSE Documentation
Operational Control
Emergency Preparedness and Response

Check Monitoring and Measurement

Evaluation of Compliance
Accident management
Non-Conformity, Corrective and Preventive Action
OHSE Records Management
Audit
Act Management Review
Table 2 OHSE MS CLAUSES

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As per safety regulations established by our Site Safety Supervisor, Muhd Izuwan
bin Suratji several guidelines have been drawn on the use of PPE (Personal Protective
Equipment). General workers should wear safety gloves at all times whilst Welders and
Fitters are required to wear welding glasses/masks, ear muffs, coveralls, and welding gloves
at all the time. Every morning, at 7.30 am, before work commences, a toolbox meeting will
be held. Toolbox meetings are Hammer Engineerings own way of conducting safety briefing
before the workers get their hands at work.

Meanwhile, as far as the project team is concerned, site visits must be accompanied by site
safety supervisor if there are installation and commissioning taking place. Otherwise, general
safety wear such as hard hats, and safety shoes should be worn all the time.

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3.12 Training Provided

It is part of Hammer Engineerings Vision to ensure every employee is provided with the
opportunity and means to obtain the knowledge and skill required to perform their work
efficiently. Every employee is encouraged to develop their abilities to the fullest in the OHSE
field.

Hammer Engineering has identified training needs associated with its OHSE risks and its
OHSE Management system. HESB shall provide training or take other actions to meet these
needs, evaluate its effectiveness and retain associated records. All new employees are made
aware of HESB OHSE risks and its OHSE Management System during the orientation or
better known as Induction Training conducted by Human Resources and Safety and Health
Officer respectively.

In addition to that, all engineers and technicians who are obliged to work at site are
required to have OGSP (Oil and Gas Safety Passport) and Green Card issued by CIDB
(Construction Industry Development Board) as per industry requirement in oil and gas plant
premises. Our clients are also strictly enforcing this regulation as this is a standard
recognition of safety awareness among staffs and would serve as elementary need before
starting work.

NIOSH-Oil and Gas Safety Passport (OGSP) System is a series of training programme
designed for specific target groups on specific OSH subjects and for a specific industry. The
system provides the appropriate training and assessment so as to ensure that the target groups
acquire the appropriate and necessary safety and health knowledge required for their jobs and
fulfill the legislative requirements and the companies policies. The series include Induction
For Plant Access to enable trainees to experience themselves with an oil and gas process
plant safety procedures and protocols.

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3.13 Standard Operating Procedure

There are many standard procedures that needs to be exercised in a company in general.
Hammer Engineering is no exception in that matter. SOPs are documented and implemented
for our recurring clients GAS MALAYSIA BHD and PETRONAS GAS BERHAD. These
SOPS varies from one company to another. It sets the difference between each company and
their standards. This sort of creates an identity for the company in a way. Therefore, SOP is
very crucial and must be followed by everyone in the company. At HESB, there are about 34
SOP. Every one of the SOP has its own set of purposes and procedure. To list all of it will
take time, therefore I would like to highlight few of the most important SOPs at HESB.
General overview of procedures and measures are listed below:-

Project Implementation Manual

Engineering Procedure

Procurement Procedure

EVC (Electronic Volume Corrector) Configuration & Validation Procedure

Fabrication and Construction Procedure

Material and Equipment Inspection Procedure

Hydrostatic Test Procedure

Factory Acceptance Test Procedure

Site Acceptance Test Procedure

Commissioning Procedure

Site Safety Procedure

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a) Hydrostatic Testing

Test pressure for the service stations shall be as per table below depending on pressure
classes of the station.

Design Pressure

Test Pressure

No

Design Class

KPAG

BARG

KPAG

BARG

1)

ANSI 300#

2483

24.83

3725

37.25

2)

ANSI 150#

400

4.00

600

6.00

Table 3 Design Pressure & Test Pressure

PRELIMINARY

1. Prior to testing, the following activities shall be completed:

2. Test section of this procedure shall be readily available.

3. Pressure gauges and recorders are properly hooked up and connected to the section to
be tested.

TEST SET-UP
This procedure shall apply for Hydrostatic Testing:

1. Install temporary blinds at each open end of the test sections. The temporary blinds
shall be of equal design class with the test section.

2. Slowly pressurize the test sections up to no more than 80% of the test pressure. Hold
the test pressure for 15 minutes during the hold time; visually inspect all the joints for
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leakage. At the same time, observe the hold pressure to see if theres any pressure
drop. If there is any leakage, it shall be rectified before proceeding to the next step.

3. After 15 minutes hold time, slowly pressurize the test sections to the test pressure.

4. The test pressure shall be held for at least 2 hours; pressure and temperature reading
shall be recorded in the pressure testing log at 15 minutes intervals.

5. After completion of testing, slowly depressurize the testing sections to the

atmospheric pressure.

6. Upon completion, Hydro testing Log shall be completed and signed DOSH and client
representative accordingly.

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b) FAT (FACTORY ACCEPTANCE TEST)

The FAT shall cover the following instruments/equipment for testing. All test equipment
have to calibrate and attach with calibration certificate before performing the test.

Functional test for :

Pressure regulators

Slam-shut valve

Pressure relief valve

Differential Pressure Gauge

Pressure gauge

Pressure chart recorder

Insulation joint

Rotary meter

Electronic Volume Corrector

Spark Gap

Leak check for:

o Screwed connection and flanges
o Pressure regulator, slam-shut valve and pressure relief valves
o Y-strainer and gas filter
o Ball valve

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3.2 Work Environment

3.21 Team work

Being exposed to people from different personalities and backgrounds certainly

provide a better insight in the working life as an engineering trainee. In the span of
approximately two and a half months (2 months) of working life, the relationship between
interns and permanent staffs that work here has been established. The staffs and general
worker acknowledge the fact that we may be still too green to understand the
concept fully, but they are always there to help.

The way things are run in Hammer Engineering, team work is given high importance. If a
problem arises, team work will help to speed up in finding the solution for the problem
instead of trying to solve it individually. Opinions and suggestions can be shared and later
discussed to check which of the following solution will help solve the problem.

Besides that, everybody in Hammer Engineering has a keen eye for quality. Our staffs
ensure everything is done right the first time, as reworks and rejects are not only
economically decapitating but also leeches on the time factor of an ongoing project. This
determination and spirit speaks volume of the efforts taken by Hammer Engineering to work
together as a team in order for continuous improvement.

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3.22 Work Ethics

Generally, staffs in the company are well trained in their daily works. The
people here are great as they always lend a helping hand. They are very cooperative in
a sense that whenever an obstacle is encountered, everybody tries to lend a helping
hand to them.

Besides that, everybody working in Hammer Engineering is always open for new
suggestions and ideas. What might work today can even be better refined on newer
ideas. This is especially being emphasized when doing engineering works as there are
varying outcomes and possible solutions to the problems faced by the company.
Actions speak louder than words. This is particularly true in Hammer Engineering.

Since this is a relatively new company, people here expect you to perform
and take action quickly instead of just empty talking. When you are delegated a task,
it is the task bearers responsibility to produce favourable results instead of just blindly
accepting the task without thinking. Therefore, achievements are constantly being
made as the staffs are always practical in whatever they meant to do.

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4.0 Work Experience

Being a project engineering trainee, I was expecting my job requirement to be mundane and
repetitive but Hammer Engineering really goes beyond my expectations. My day-to-day
activities has been both challenging and rewarding in terms of valuable experience field
handy skills.

I feel the need to elaborate on the job scope of project engineer in Hammer Engineering as
different companies has different project running under them and the requirements might
differ.

Project Engineering bridges the boundary between engineering and project management,
leading the technical workers who contribute to the building of structures or products. In
some cases, the project engineer is the same as a project manager but in most cases these two
professionals have joint responsibility for leading a project. Project management holds
responsibility of every field of engineers

Project Engineers are required to;

Liaise between project manager and other technical disciplines in the project
Review project proposals, identify project phase, ensure project follows schedule
Coordination of work between vendors, sub-contractors, local authorities and client
Generating relevant document for project deliverables as per client requirements
Project cost control through effective project scheduling and minimizing project cost
and expenses
Meeting deadlines as stipulated
Sourcing the most competitive but yet the reliable products, bulk materials and
consumables for the project
Inter-discipline coordination throughout project execution during engineering,
procurement, construction and commissioning phases.

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4.1 Skills Gained

i.

Microsoft Project:

This is the ultimate project management tool and used widely in the field of project
management and Hammer Engineering is no exception that rule. Through my participation in
various projects, I have been using Microsoft Project to review and analyse the Master
Project Schedule throughout all project phases and provide feedback to my supervisor in case
of any discrepancies in the schedule, eg : in meeting stipulated deadlines, submitting
purchase requisition, sourcing the materials and so on.

ii.

AutoCAD 2014:

The significance of this software cannot be thanked enough in our company, or at least in my
line of work. Apart from the original engineering drawings, we are also required to redraw an
as built drawing upon completion of fabrication. Somewhere, along the line between
material inspection and fit-up, I am required to produce weld maps to indicate joints weld in
the particular station. This will be the primary document when requesting the services of
NDT Inspector/Technician as we would need an accurate depiction of quantities of weld
joints to be inspected.

iii.

QNE 2015:

Project cost control is established with thorough planning of purchases of materials and
sourcing of services. The link that bridges that gap is this accounting software. Throughout
my internship period, I had been doing more purchase requisition than I can ever keep count
for a number of ongoing projects. As we emerge as a cost-efficient competitor in the industry,
it is vital that the Managing Director oversees most of the purchases.

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The procurement department had always had keen eye for detail as they would always liaise
with us to source the most competitive product before releasing the purchase orders made
based on submitted purchase requisition. All these details are stored in this accounting
software, which would help with bookkeeping and audits.

iv.

Microsoft Excel:

Fresh from university, my Microsoft Excel skills were only on par with other students but
now I am pretty sure my fluency in this doubled since I started working here. My supervisor
himself, Mr. Eh San is an excellent user of Microsoft Excel. Starting from developing simple
databases to using pivot table functions, he taught me most things that would come in handy
in my future ventures that involves the use of this software.

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4.11 Communication Skills:

Soft skills are important in any company. In Hammer Engineering I was assigned the
responsibility of handling the documents that requires approval by managers and supervisors
I was able to establish great channel for communication between my department and other
department thereby reducing possible communication barriers. Having the chance of working
with people from various levels in the organisation has definitely helped me in further
enhancing my soft skills.

Communication in the company can be divided into formal and informal.

Formal communication includes conversation or meetings with senior engineers and
contractors while the latter includes conversation with staffs in the office and general workers
doing the fabrication. It is a priority to converse in English language when in formal
meetings. Not only that, technical terms are being used over and over again so as to have a
general understanding by the people attended for the meeting.

However, informal communications work completely opposite with its counterpart. Informal
communications between staffs and colleagues enhances the relationship between one
another and is less of a serious atmosphere compared to formal communications. It can be
said that both communication skills are well practised by me and is being improved over the
course of time working in the company.

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4.12 Time management:

Time management is something everyone have to cope off when working in the future. Being
an intern in Hammer Engineering, Im assigned with daily tasks as well as handling two to
three projects at the same time. With so many things on hand, time management plays a
crucial role in my daily working life. Managing all these tasks is hard but not impossible.
However, unforeseen circumstances may occur once in a while. Working and sitting for
examinations are two different things. In an examination, we are required to be objective in
the answering the questions. But in the working life, it is more subjective and most of the
tasks are subjected to changes.

4.13 Initiative:

In terms of initiative-wise, I could say that exposing myself out in Hammer Engineering
really does made me more initiative driven. This is because jobs that are given to me are
expected to be completed in the timeframe given. However, most of the tasks given are not
what we had studied in university but rather something more advance.

In order to complete the task successfully, I have to take initiative to ask around who are
related to the matter on hand. A crude example for this scenario would be the database
project that I have been assigned. It can be concluded that initiative in me as a character has
helped me a lot in solving my daily activities as well as learning new things at the same time.

In a nutshell, the skills that I have obtained and polished until the present day are numerous
but the ones that really do shine out is that I am able to lead, plan, communicate well and
become a proactive character.

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4.2 Knowledge

4.21 Understanding job requirement

Only after I started working in Hammer Engineering, I realised that project engineers do not
do design work, but instead represent the contractor out in the field, help tradespeople
interpret the job's designs, ensure the job is constructed according to the project plans, and
assist project controls, including budgeting, scheduling, and planning.

In some cases a project engineer is responsible for assisting the assigned project manager
with regard to design and a project and with the execution of one or more simultaneous
projects in accordance with a valid, executed contract, per company policies and procedures
and work instructions for customized and standardized plants.

Typical responsibilities may include: daily operations of field work activities and
organization of subcontractors; coordination of the implementation of a project, ensuring it is
being built correctly, project schedules and forecasts, interpretation of drawings for
tradesmen, review of engineering deliverables, regular project status reports, budget
monitoring and trend tracking, bill of materials creation and maintenance, effective
communications between engineering, technical, construction, and project controls groups,
and assistance to the project manager.

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4.22 Completing task on a given time

Everyone has the same amount of time available to them. We cannot control time, but we can
learn to use it more efficiently and effectively by planning carefully. Having training for my
internship in here had taught me a lot in managing my time especially when the tasks were
given and I need to complete it within a short period of time. Sometimes it may seem that
there isn't enough time for me to do everything that I need to. Moreover, I have learnt that
once we have identified ways in which we can improve the management of our time, we can
begin to adjust our routines to manage our time effectively. One of my ways that I have been
practice is start listing the tasks based on their priorities. Conclusively, using time effectively
involves making choices that produce positive results especially when the task is completed
the way I want.

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5.0 Discussions on Sustainability

5.1 Environmental

Its Hammer Engineerings policy to always comply with the rules and regulations set by the
company itself or government regarding the balance of environmental and economic needs of
the community. Being placed in a sub-urban area, the plant is situated in an area which is
secluded and almost 70% of the place is undeveloped. Therefore, there is minimal damage to
neighbouring communities if anything were to go wrong in the yard. Ample of time is given
for evacuation and hence it states the amount of precaution taken regarding their
surroundings and not only focused to their production.

There are no chemical processes taking place in our yard meaning that there are no chemical
wastes or toxic sewages that needs handling with extra caution. Even then, Hammer
Engineering takes deliberate effort to ensure drains are not leached with metal wastes like
welded shrapnel and metal dusts to prevent it from clogging. Clogging would lead the water
flow to be stilled and this would emulate the growth of algae, mosquitos, and other unwanted
biological hazards. Hence, this speaks volume of the effort taken by this company to health
and environment.

Staffs and top executives at Hammer Engineering also place personal safety, industrial
hygiene, environmental performance and operation at its highest priority. Hammer
Engineering hires the service of an external waste management company to clear out solid
wastes on regular time period. As far as paper waste is concerned, recycled papers are used
for printing purposes so that no paper is being wasted in our offices.

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5.2 Economical

Since 2009, when Hammer Engineering first begun operation till this date, Hammer
Engineering has exponentially grown as an aggressive player in the industry, winning most
tenders from national gas distribution company, GAS MALAYSIA BERHAD. In the past
few years alone, it can be safely assumed that almost 80% of their projects have been
successfully executed by Hammer Engineering.

Refusing to settle down comfortably, Hammer Engineering has also ventured into sales of oil
and gas equipments by being the supplier for Byho Valves, Nirmal Pressure Regulator and
Daggaz Odorizer. Owing to its international collaboration, Hammer Engineering has a
significantly better price to offer in its tenders for its products compared to similar companies
in the industry. Sourcing equipments for a better price and better quality has always been
done by most companies seeking marketability and diversity but Hammer Engineerings has
always had an eye for quality and that is what had brought them to the position they are now.

Hammer Engineering has plans to expand further and has projected plans to move to a
factory site which is still under construction; an expected shift of operations to the new site
shall commence in a years time. Meanwhile, Hammer Engineering has moved its
administration office to the fancy new place in Gamuda Walk, Kota Kemuning. The biz
suites in Gamuda Walk offers authenticity and professional experience to our clients
compared to our current location which has a bit of traditional, conventional touch.

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5.3 Political and Cultural Dimensions

This would be a relatively complex topic to bring about in a discussion but nevertheless I had
always had pondered upon it. Before even I started working in here I had a very misleading
perception about working life and working culture in Malaysia. Owing to my experience in
Government Service Sector offices, where I have encountered processes which are extremely
time consuming and people who practice procrastination hastily, I have always had a thought
that Malaysian companies would share the same culture. But, to my awe and surprise
Hammer Engineering is pound-for-pound an exemplary portrayal of the virtue of hard work.

What started as a 6-man team has grown into an excellence amassing juggernaut in the
industry all thanks to their relentless effort on a mutual goal: TO DELIVER BEYOND
EXPECTATION. It is evident in an EPC company the trend where the work intensifies upon
reaching a stipulated deadline and work is not bound to completion. This is when our staffs
are put to the test. Week in, week out, I observe the stress and the salvage that is brought
about by the amount of diligence that has been put to practice. In spite of that, Hammer
Engineering staffs has hurdles through just fine in terms of managing the workload
throughout the many phases of the project to meet the deadline whilst maintaining a stringent
quality of its product and services.

As far as political dimensions are concerned, the demand for liquefied natural gas has grown
significantly. Since the price of crude oil is on an ever increasing trend, many consumers are
converting to liquefied natural gas for their energy consumption needs. This in turn increases
the number of LNG refuelling stations where Hammer Engineerings expertise would be
needed. In addition that, the rapid growth of industries in Malaysia has also created a large
demand for industrial power generation. The most economical and environmental source of
fuel for steam boiler at the time being is LNG ( liquefied natural gas) and hence more
requests are being made by companies to GAS MALAYSIA BHD pertaining installation of
gas metering and regulating stations gas transmission to their company as a feed for steam
boiler.

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6.0 Conclusions

In my honest opinion, internship serves as a platform for every student to learn as much as
they can about the real working life. This will be an advantage to us in the future because we
will not take a very long time to get settled in a company because we already know what to
expect. Other than that, technical skills and knowledge gained during internship can also be
used as guidance during our final year projects. Non-technical skills such as communication
skills, teamwork, safety awareness, leadership and management have also been taught during
the internship training.

Any weakness we possess should be dealt with during this training as it can make us
confident and be bold of our decisions and etc. In the real working world, we will not be
guided anymore. Therefore, this is the best chance to learn as much as we can and later apply
that knowledge in the company that we are going to work.

Internship has also taught me about the safety regulations and its importance. There is never
a grey area in safety. We should always think about our safety first before performing any
work in the near future. Safety is an essential part of any working field whether in the oil and
gas industry or in such power plants like this. In a nutshell, this industrial program is a
turning point for each of us regardless of the company that we have been selected to train. It
is also a way for us to express our inner abilities that it we once thought it was never there.

In addition to that, learning from the mistakes and build ourselves up is what I feel every
intern should remember and never give up whatever the circumstances may be. Lastly, I am
really fortuned to undergo this training program with my Host Company, Hammer
Engineering Sdn Bhd. They have taught me a lot and I would never be able to thank them
enough for finishing off this internship on a high note.

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Recommendations:

I would like to express a few recommendations that could be done in order to make this
internship even more beneficial and effective.

1. I would strongly encourage the students to apply for pre-internship before going for their
intern. - This is simply because there are a lot more to learn and 8 weeks is just not enough to
grasp all the understanding. Therefore, a good head start will come in handy during the
internship program.

2. Maintain the period of Internship and its pattern. - UTP is one of the few universities that
apply this type of internship program. Its difficult to find any other universities that would
do the same. Therefore, this is a big advantage for UTP students. The separation of training
and project is a good idea because in order to perform the certain project, one should undergo
a good training.

Best Regards,
Anderson Joseph,
Engineering Trainee,
Hammer Engineering Sdn. Bhd.

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References:

www.hammer.com.my,. (2015) What We Do - Our Principal Activities.

Retrieved 7th July 2015 from,
http://www.hammer.com.my/what-we-do/principal-activities.html

www.daggaz.com,. (2015) DAGGAZ LPG-NG INJECTION TYPE ODORIZING SYSTEM.

Retrieved 29th June 2015 from,
http://www.daggaz.com/energy/urunler/kokulandirma-sistemleri/daggaz-odorizers/

www.byhovalve.com,. (2015) Home Products Ball Valves Floating Ball Valve.

Retrieved 29th June 2015 from,
http://www.byhovalve.com/products/products-512.html

www.nirmalindustries.com,. (2015) GAS PRESSURE REGULATOR - D53 /- Series.

Retrieved 29th June 2015 from,
http://www.nirmalindustries.com/pressure_regulators_d53.html

www.niosh.com.my,. (2015) NIOSH SAFETY PASSPORT > Oil & Gas Safety Passport
(OGSP). Retrieved 29th June 2015 from,
http://www.niosh.com.my/nsp/?page_id=2

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Glossary

Fit up Line pipe and equipments that has been tack weld together as spools according to
dimensions in the drawing.

Hook up Fully weld spools are connected together by means of nuts/bolts/screws and made
into one part.

NDT- Non Destructive Testing- a wide range of tests on welded media that would indicate
cracks in the radiograph, indicate a clear surface without penetrant captured in cracks without
causing anomaly to its initial condition.

RT- Radiography Testing- A type of NDT testing that involves radioactive rays such as X-ray
and/or Gamma ray

FAT- Factory Acceptance Test- Quality testing procedure done at contractors site to prove
the functionality of product to client, witnessed by client.

SAT Site Acceptance Test Quality Testing procedure done at clients site to prove the
functionality of product to client, witnessed by client.

PLC-Programmable Logic Controller is an industrial computer control system that

continuously monitors the state of input devices and makes decisions based upon a custom
program to control the state of output devices.

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