SIX WEEKS INTERNSHIP PROGRAM

REPORT
LNG ACADEMY VI

WRITTEN BY
ELITA KABAYEVA - 6516010072

MECHANICAL & ROTATING ENGINEERING

LNG ACADEMY
2018
 PREFACE

Praise to God that it is because of His mercy and blessings, we can complete
the 6 weeks Intership Program and finished writing this 6 weeks Internship Program
Report. This report is arranged as one criteria after we fiinished the internship
program, along with the accountability presentation about one working activities in
the internship program.
The purpose of the Internship Program is to encourage students in gaining
working experience and enrinchen their views about the field work through hands-
on approach. This internship program was held in 6 weeks, divided to 3 sections.
Thus resulting 2 weeks in each sections.
In this report, will be explained things that the writer has been learning in
each sections. Also covering the cases and the solutions found in the field while the
writer is at it.
For your attention and cooperation, we would like to thank you.

Balikpapan, February 9th 2018

Sincerely yours,

Elita Kabayeva
 SECTION I
FOREWORD

1. Background
Internship Program is a program from the committee board of LNG
Academy, as a way of providing learning access to the students through hands-on
activities, which prevail to all students of LNG Academy whom already completed
their 3rd term of school year. As a college student whom already studied many basic
theories in the college, those things would not be completed without the aid of skills
to be able to apply the theories in the company or industry. To gain the goals, thus
this Internship Program is aimed to give chance for the students to prepare
themselves with various experiences befores stepping in into the working stage.
The internship program differs into three different schedules. Each for
students in their own specialization. For this report, as for the writer has the
Mechanical & Rotating specialization, the internship program specificated itself
into three different sections. Those are :
1. Machinery and Heavy Equipment Section, whereas the writer was assigned in
the Predictive Maintenance Subsection.
2. Stationary Equipment and Construction Section, whereas the writer was
assigned in the Preventive Maintenance Subsection.
3. Facilities & Project Engineering Section
With these subsections assigned this is a proper medium to support the
understanding of theory application for the students.

2. Scope
In this occasion, writer did the Internship Program in three different sections
whereas in those sections, being assigned to subsections. Writer studied information
about division of work and work scope specificated in the subsections which are
quite different from each other.
 While in each sections, writer followed the working activities and observed
directly on field. Thus, the informaton gained was based on real time observation
and interviewing the workers. The evaluation gained was mainly from the
mechanics (based on experiences) and then being cross checked to the engineers,
also rechecked from the historical data of the problem.

3. Goals and Benefits

3.1 Goals
3.1.1. General Aims
a. Fulfill one criteria from the LNG Academy as the post-internship program task.
b. Apply and compare the theories gained in class with the observation of the real-
time working activities, in relation with the sections discussed individually.
c. Knowing the working divisions in several sections of Badak LNG maintenance
department.
d. Knowing the working activities in several sections of Badak LNG maintenance
department.
3.1.2 Special Aims
a. Students learning of how solving problems found while working in each
subsections assigned.
b. Students able to compare the recommendation in the field and give additional
recommendation via presentation, thus the working activities might turned out
to be better and efficient from the evaluation given.
3.1.3 Benefits
a. Students able to apply their abilities in projects/industries corresponding with
their skills gained in the class.
b. Students able to complete the tasks given by the subsections assigned
corresponding with the quality goals and accuracy needed.
c. Students able to make proper Internship Program Report.
d. Train the students’ skills to be an independent person, have good manners, able
to solve problems and take judgement during working.
e. Enhance the social interaction skills with other people in the industrial area.

4. Internship Program Report Writing System

In the writing of the Internship Program report, the writing system used is
as followed :
1. Section I : Foreword. This section is about the Background, Scope, Goals and
Benefits of the Internship Program, and Intership Program Report Writing
System.
2. Section II : Machinery and Heavy Equipment section. This section is about the
2 weeks internship program in MHE Section, specificated in Predictive
Maintenance subsection.
3. Section III : Stationary Equipment and Construction section. This section is
about the 2 weeks internship program in SE&C Section, specificated in
Preventive Maintenance subsection.
4. Section IV : Facilities & Project Engineering section. This section is about the
2 weeks internship program in F&PE Section.
5. Section V : Conclusions and Suggestions. This section is about the general
conclusion gained from the 6 weeks of the internship program, specific
conclusions gained from each subsections assigned, general suggestions given
to the 6 weeks of the internship program, and specific conclusions given to each
subsections assigned.
6. Section VI : Closing.
 SECTION II
MACHINERY AND HEAVY EQUIPMENT
SECTION

1. Machinery and Heavy Equipment Section Overview

The Machinery and Heavy Equipment Section is a section under the
Maintenance department which working area covers all plants in Badak LNG,
specifically the rotating equipments in each plant.
This section has four workshops; welding shop, valve shop, machining
shop, and rotating shop and five subsections; Utilities I, Utilities II, Predictive
Maintenance, Preventive Maintenance, Storage Loading and Marine.
Each subsections specificate their working activities in each assigned
working area. Maintaining the performance of the rotating equipments supporting
each area, in different way of working divisions.

2. Predictive Maintenance Subsection

As the subsection being assigned for the internship program, Predictive
Maintenance covers all plant area of Badak LNG. Predictive Maintenance
subsection maintains the performance of the equipments by predicting the lifetime
of the equipments and kinds of the failure which might happen through reading their
vibrations. Aside from reading vibration, the Predictive Maintenance subsection
also conducts Balancing and Alignment.
The working activities is given to the Predictive Maintenance subsection by
giving working request which will be further processed to a working permit before
it is being executed on field by the mechanics.
The vibration test requested is usually held to the equipments after they are
being repaired to check whether the equipment is running smoothly and there is no
imbalance in the equipments’ rotor. The vibration normally would not touch the
number of zero. But majority of the equipments usually have the normal vibration
number below 0.1 ips (inch per second) and for the Cooling Water Motor, the
normal vibration number is below 0.25 ips. In the meanwhile, the daily vibration
test is usually held for predicting the lifetime of the equipments and knowing any
abnormalities in the equipment, which by it could be an indication for the equipment
to be repaired by the subsection responsible.
2.1 Field Static Balancing of Cooling Water Motor 32-GM-16
One interesting requested case from the Machinery and Heavy Equipment
was the field static balancing of cooling water motor 32-GM-16. Since the
equipment was being idle for almost 8 months.
The cooling water motor vibration was taken as a daily vibration taking and
the result was quite shocking since it is above 0.25 ips, in other meaning, the value
is high in measurement. Then, it was decided to uncouple the motor from it’s pump
and open the top cover of the motor. Two days after, the motor was being vibration
tested again while in solo run. The result decreased. Although it was below 0.25
ips, it still be considered as high. After that, the field static balancing was conducted.
Field balancing is a technique used to balance a rotating part in place without
removing the part from the machine, and Static balancing is a technique used when
we only balance the rotating part where we read it’s vibration and neglect the
vibration in other parts.
In this case, we do the static balancing in the motor fan. We take the solo
run vibration data as our Original Run Data. For the probe placement places it was
installed in four point, the motor top east, motor top south, motor bottom east, and
motor bottom south. But, for the calculation taken after the Original Run Data, the
motor bottom south reading was neglected since the location was unreachable. As
for the referrence calculation, we use the highest level vibration from the original
run data. From the CSI Analyzer, we got the phase where the imbalance is located
on the fan.
 Next step, we add temporary correction weight, 180 degree from the
imbalance phase of the original run data. The value added was 306 gram, based on
previous filed static balancing data. It was added at approximately 270 degree. After
that, we run the motor again and take the Temporary Correction Weight Data.
The vibration result decreased but it was still above normal vibration value.

Thus, in order to take revise the correction weight, we drew the diagram on
the Form Polar Plot. On the polar plot, we drew in vector. First off the original run
without trial mass, then the trial run with trial mass. After that we connect the two
vectors. Then we projected the resulting vector to get the correction mass needed to
balance the fan.

The trial mass was corrected into 613 gram at 226 degree from previously
305 grams at 270 degree. Thus, the trial mass was added 308 grams into it. After
that we did the solo run again and take the 2nd Temporary Correction Weight
Data. And the result was decreasing a bit much from previous run.
 After that, the temporary correction weight was changed into permanent
weight. But, due to the limit of the permanent weight, the weight used was a bit
different from the last temporary correction weight, resulting in different result for
the vibration taken of the cooling water motor.

SECTION III
STATIONARY EQUIPMENT AND CONSTRUCTION
SECTION
1. Stationary Equipment and Construction Section Overview
The Stationary Equipment and Construction Section is a section under the
Maintenance department, similar with the Machinery and Heavy Equipment
Section, which working area covers all plants in Badak LNG, specifically the
stationary equipment and construction in each plant.
Describing the SE&C working activities, the subsections are divided into
each area of plant such as Utilities I & II, Storage Loading & Marine, Process Train,
Preventive Maintenance, and FIP (Fiberglass, Insulation, and Painting).
Each subsections specificate their working activities in each assigned
working areas. Maintaining the performance of the stationary equipment supporting
each area, and the construction of the plant, in different way of working divisions.
One thing we need to highlight in the SE&C section is the way the Toolbox
Meeting is arranged. In the previous section, the MHE section, the toolbox is
arranged separately in each subsections & workshops, individually. But, in the
SE&C section, the Toolbox Meeting is arranged each morning together in the 1st
floor of the building. The workers are all gathered there, divided into small circles,
based on their subsections of working.

2. Preventive Maintenance Subsection

The subsection assigned in this section was the Preventive Maintenance and
the subsection covers all plant area of Badak LNG. Preventive Maintenance, for
short, is a planned maintenance activity which is being executed towards an
equipment, aiming to prolong the equipment’s reliability, also to unplanned reduce
repairing activity, aiming for the decrease of maintenance cost used.
Preventive Maintenance is classified into several classes, based on their
time. Below are several examples for each time-based classes in Preventive
Maintenance :
1. Greasing Boving Valve (1 Month, 3 Months)
2. Greasing Loading Arm (1Month, 3 Months)
3. Cleaning Strainer (2 Months)
4. Cleaning Temporary Net (2 Months)
5. Heat Exchanger —> Lube Oil Cooler, Intercooler (6 Months, 1 Year, 1.5 Years,
3 Years)
6. Suction Strainer (6 Months, 1 Year, 1.5 Years, 3 Years)
Thus, the working activities are directly given from the MPTA Planner
directly for the PM Program. And then, given to the supervisor of the PM
Subsection, for the working permit to be made and next the working activities are
distributed to the workers to be executed. After being executed, it is for the closing
and then for the evaluation.
Since it is scheduled, the working activities can be reported as follow. For
the first day, the working activities was to lift the temporary net in plant 32. The
Jellyfish net condition was clean and no damaged part found. For the following
days, the scheduled working activities which being observed :

• Cleaning Lube Oil Cooler of 2-E-5 —> the working activities followed the
procedure in the working instruction of how to open the equipment and clean the
lube oil cooler. But, one thing to be highlighted was the lube oil inside the
 equipment had not been emptied by the operator in charge, the night before. So,
the lube oil inside the equipment was wasted. For the cooler condition, based on
the Inspection result, was still good and thus the only thing replaced was the O-
Ring and gasket.

• Cleaning Generator Air Cooler of 31-E-115A/B —> the working activities

followed the procedure in the working instruction of how to open the equipment
and clean the generator air cooler. To be noted, there are 4 anodes on the lube oil
cooler. The front one shall be replaced, since the anodes already corroded much.

• Cleaning Jellyfish Temporary Net, 32-JFS-16 —> the working activities

followed the procedure in the working instruction of how to lift the jellyfish
temporary net. Beside of the cleaning, the bottom part of the temporary net was
found damaged heavily because of the frail condition, so it was replaced.

• Cleaning of Hayward Strainer, 32-T-5E —> the working activities followed the
procedure in the working instruction of how to open the hayward strainer. Before
any working activities could be done, it shall wait the operator in charge to block
the flow in the equipment by using amri valve and boving valve, then drain the
water inside the hayward strainer. After opening the manway, gas test shall be
conducted and after that the cleaning activities could be done, usually it use utility
water, if it can not clean the equipment, checmical is used. One thing to be
highlighted is, this working activities could not be done in the very day, because
of the amri valve was cracked, so the operator in charge could not allow the
working activities to be continued. It was done in the next day, after the problem
in the amri valve was already done.

• Travelling screen anode replacement, 32-T-6E —> the result for the anodes were
all still in good condition, between 70%-100%, No need to replace it.

• Cleaning of Lube Oil Cooler, 32-E-6 —> this is similar with 2-E-5, without the
shell cover. This equipment is used for cooling the lube oil by using sea water.
Thus, this only need to be cleaned by using utility water and utility air.

• Cleaning Bucket Strainer 14 inches-18 inches, 31-G-113 —> the working

activities followed the procedure in the working instruction. Before any working
 activities could be executed, the flow shall be blocked. Then, the operator in
charge, attached the LOTO followed by draining. One thing to be highlighted, in
the process to open the cover, one bolt was stuck, so it need to be sawn manually
and then replaced. Meanwhile the other bolts were greased by using lube oil.

• Cleaning of Lube Oil Cooler, 31-E-87 —> the working activities followed the
procedure in the working instruction of how to open the equipment and clean the
lube oil cooler. This is similar with 2-E-5 and 32-E-6, only without shell cover.
And in this lube oil cooler, 1/2 inches pencil anodes were used, and it was heavily
corroded so it needs to be replaced.

• Cleaning Seal Water of Boiler Feed Water Pump, 31-E-92A/B —> the working
activities followed the procedure in the working instruction of how to open the
equipment and clean the seal water by using utility water and wire brush.
2.1 Cleaning Jellyfish Temporary Net, 32-JFS-16
This is one working activities which I observed and it needs a few
highlights, so in order to be able to explain it, this was made into separate part. On
January 3rd 2018, the 2 Months Preventive Maintenance Cleaning Jellyfish
Temporary Net, 32-JFS-16 was conducted. And for the result of the working
activities, the bottom part of the Temporary Net was severely damaged, so the
replacement action was conducted.

Moreover the cleaning action used in the water basin, in case there is
jellyfish inside it, can be counted as unsafe act. Since worker ought to stand on top
 of a bucket, moved by an overhead crane. There could be cases of falling down
and/or overhead crane damage, since overhead crane is not designed to carry
fluctuating weight (in meaning, human, since human can move so the emphasis will
move as well).

Thus for those highlights, there are a few suggestions that could be
Factor considered
Cause : Effect Solution Result and Risk

Material Small net Thin temporary Add bottom net - Durable temporary net
net, easily into 2 layers - Add more net material
diameter damaged by
trash’s weight

Method No other Manual cleaning Modify - Outflow for modifying case

which is temporary net - Safer PM Working
method uneffective with the activities
installment of - Efficiency will increase.
intermediate
Tools No special tool Using bucket and temporary net on
man the basin
 SECTION IV
FACILITIES & PROJECT ENGINEERING
SECTION
1. Facilities & Project Engineering Section
Located in the TOP Building, Facilities and Project Engineering is a section
under the Technical Department. Which working activities covers the project done
in Badak LNG, including the shipping and docking process.
One of the project is the Ship Shore Compatibility Project. With the title
said, it is a project which is done every new LNG/LPG ship come to the Badak
LNG dock. In order to know whether the ship is compatible with Badak LNG’s
dock compatibility or not, we need to plot the drawing of the ships with Auto CAD
software. Below is the example from Kvaerner-Moss Spherical Tank general
drawing which need to be plotted :

and below is the example of the already plotted general drawing :

 From the plotted drawing, we will get the value needed for the compatibility
test. Such as the Summer draught, Ballast draught, Deadweight, and Displacement.
But, in addition, not all values needed should be obtained from the plotting. There
are accompaniment files attached to each ship, with ship’s specifications written.
Below is the example of one accompaniment file for LNG ship, Grace Barleria,
LNG form B.
 All of the values needed are inputted into a template for calculation in
Microsoft Excel. Thus, after all values are already inputted, then it will be known,
whether the ship is compatible or not with the dock.

To be noted, the calculation used for LNG and LPG ships are different and
each has their own templates. Below is the example for LNG ship Grace Barleria
Microsoft Excel
file.
 SECTION V
CONCLUSIONS & SUGGESTIONS
SECTION
1. Conclusions
- The 6 Weeks Internship Program is to make student could achieve on-hand job
experience on field.
- In this program, 3 sections were assigned, with three subsections, one for each
section : MHE, Predictive Maintenance ; SE&C, Preventive Maintenance; FPE.
- Each subsections have different way of working division, working activities, and
working area.
- Machinery and Heavy Equipment is a section under the Maintenance
Department, which working area covers all rotating equipment in Badak LNG
plant. It has four workshops; welding shop, valve shop, machining shop, and
rotating shop and five subsections; Utilities I, Utilities II, Predictive
Maintenance, Preventive Maintenance, Storage Loading and Marine. In the
Predictive Maintenance subsection,maintains the performance of the equipments
by predicting the lifetime of the equipments and kinds of the failure which might
happen through reading their vibrations. Aside from reading vibration, the
 Predictive Maintenance subsection also conducts Balancing and Alignment. The
working activities is given to the Predictive Maintenance subsection by giving
working request which will be further processed to a working permit before it is
being executed on field by the mechanics.
- Stationary Equipment and Construction is a section under the Maintenance
Department, which working area covers all stationary equipment in Badak LNG
plant . The subsections are divided into each area of plant such as Utilities I &
II, Storage Loading & Marine, Process Train, Preventive Maintenance, and FIP
(Fiberglass, Insulation, and Painting). Preventive Maintenance, for short, is a
planned maintenance activity which is being executed towards an equipment,
aiming to prolong the equipment’s reliability, also to unplanned reduce repairing
activity, aiming for the decrease of maintenance cost used. The working
activities are directly given from the MPTA Planner directly for the PM Program.
And then, given to the supervisor of the PM Subsection, for the working permit
to be made and next the working activities are distributed to the workers to be
executed. After being executed, it is for the closing and then for the evaluation.
- Facilites & Project Engineering is a section under the Technical Department.
Which working activities covers the project done in Badak LNG, including the
shipping and docking process.
One of the project is the Ship Shore Compatibility Project. With the title
said, it is a project which is done every new LNG/LPG ship come to the Badak
LNG dock. In order ro know whether the ship is compatible with Badak LNG’s
dock compatibility or not.

2. Suggestions
- Maintain the internship program guide and close to current field work method
which already done, and might be improved for a better result.
- There are some cases while in the intership training program which could not be
tracked from the library in each section, but rather spread around the
Inspectors/Engineers on charge, improvement for a better archiving might be
 good, in order to have historical data as the basis if similar case happen in the
future.
- Daily recommendation archiving from Inspection section for daily working
activities could be a good improvement for historical data in Preventive
Maintenance subsection.
- Improvement from time-based Preventive Maintenance to condition-based
Preventive Maintenance might be a good improvement for some critical
equipments.

SECTION VI
CLOSING
That will conclude this report. I hope this report could help to explain in
brief the six weeks intership program in three sections of Badak LNG. Hopefully
there are some critics and suggestions in order to improve this report. We would
like to thank for the attention and help from all parties.

Balikpapan, February 9th 2018

Elita Kabayeva