INDUSTRIAL TRAINING REPORT

UMW ADVANTECH SDN BHD, JALAN UTAS 15/7,40915

SHAH ALAM, SELANGOR DARUL EHSAN

MUHAMAD SYAZMIL ILHAM BIN ABDUL MALIK

2018213158

Faculty of Chemical Engineering

UNIVERSITI TEKNOLOGI MARA

MAY 2019

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TABLE OF CONTENT

Content Page

Introduction 3

Organization chart 4-5

History of company 6-8

Process flow 9 - 12

Daily activities 13 - 16

Task assigned 17

Conclusion 18

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INTRODUCTION

Industrial training is a mandatory requirement that all student of UiTM Bukit

Besi in order to complete my graduation. Industrial is a documented report of
training experience undergone by students. All chemical engineering student will
undergo their industrial training on 17 February until 23 March 2019 which is around
3 months.

The main purpose of this industrial training is to give students a vast exposure
to the real industrial environment. In addition, students were able to apply their skills
that they have learned through their academic years. Besides, students were able to
widen their knowledge and abilities as well as soft skills at the companies they will
be performing their industrial training by interacting with colleagues and customers.

I was given opportunity to perform my industrial training in PETRONAS

Chemicals Olefins Sdn Bhd which was an organization that was fully owned by
PETRONAS Chemical Group (PCG) located in Kerteh, Terengganu. During my
industrial training, I was assigned to area D which is heavy separation area. A team
of five person including myself assigned directly under our supervisor, Mr Faris Bin
Abd Halim.

Several task need to be done along our industrial training which are field
related activities and outside field activities. All the task and work progress directly
reported to Mr Faris Abd Halim, Process Engineer for heavy separation area.

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ORGANIZATION CHART

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5
HISTORY OF COMPANY

PETRONAS Chemical Group (PCG) is the leading integrated chemicals

producer in Malaysia and one of the largest in South East Asia. The company operate
a number of world class production sites, which are fully integrated from feedstock
to downstream end products.

With a total combined production of 10 million metric tonnes per annum

(mtpa). PCG are involved primarily in manufacturing, marketing and selling a
diversified range of chemical products, including olefins, polymers, fertilizers,
methanol and other basic chemicals and derivatives product.

The company story as a leading petrochemical group began as early as 1996

when the idea behind a world class petrochemical facility was coined via Letter of

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Intent between Union Carbide Corporation and Petroliam National Berhad
(PETRONAS). After two years of wait, in 1998 a Joint Venture Agreement was
finally signed between the two. The group was formed under the name OPTIMAL
group companies. Work began soon after with the clearing of the grounds for the
future OPTIMAL petrochemical plant in Kerteh, Terengganu, Malaysia.

In 2002, Union Carbide Corporation’s stake in the group was taken over by the
Dow Chemical Company (Dow), a diversified industry-leading global giant with a
portfolio of specialty chemicals, advanced materials, agro sciences and plastics
business that delivers a broad range of technology-based product and solutions.
January 2002, marked a momentous occasion for the Group. The first on-spec
ethylene was produce-the new chapter from project stage to a fully operational
petrochemical company had begun. The operation of the finals reactor in the
OPTIMAL complex in October 2000 recorded the completion of the project phase
and named the OPTIMAL Group Companies.

In 2010, PETRONAS acquired all the share owned by Dow which

subsequently led to the OPTIMAL Group becoming part of PCG. This became a
turning point for PETRONAS as PCG became a member of a focused, driven Group
under the PETRONAS family.

There are total of 13 companies which were wholly-owned and six companies
that are partly-owned by PCG management as shown in Table 2.0. Apart from
managing companies from Malaysia, PCG also responsible to manage company from
India. It clearly shows the management responsibility which is not easy and could
never be ignored. In Malaysia most of PCG plants are focused on the East Coast side
which is Kerteh, Terengganu.

PETRONAS Chemical Olefins Plant is the largest plant in PETRONAS

Petroleum Industry Complex. Currently, it has staff force of 73.

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 Comprising both Malaysians and expatriates. The plant is led by En. Wan
Syahrul Anuar Wan Zin as the Head of Department. There are 3 areas of operations
which are Hot Side, Heavy Separation and Light Separation. Table below shows the
operation details of Olefin Department.

 Hot Side comprises Furnace area, Hot Rover and Quench area.
 Heavy Separation consists of Cracked Gas Compressor and Heavy
Separation.
 Light Separation consists of Light Separation and Cold Rover.

Share Holders - PETRONAS (88%)

- SASOL (12%)
Main Products - ~630kTa Ethylene
- ~95kTa Propylene
- ~35kTa Pyrolysis Gasoline
By-Products - Hydrogen to Butanol
- Methane to EOG &
Butanol
- Tailgas (H2 and CH4) to
Sales gas via Utilities.
- C4’s to Furnace as fuel.
- Heavy oil to incinerator.
Milestone  Plant Start up on January 27,
2002. On spec
Ethylene(product) on January
31, 2002.

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 - 1st Plant Turn Around
(TA) on 2003.
- 2nd Plant TA on 2005
 Empowerment stage one, May
2008.
- 3rd Plant TA on 2009
- 4th Plant TA on 2013.

PROCESS FLOW (OVERALL)

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 In general, process flow for olefins plant divided into three section which are
hot side (furnace, quench, hot rover), heavy separation (cracked gas compressor,
heavy separation) and light separation (cold rover, light separation).

The Olefins unit at PCOGD will crack Ethane and Propane into Ethylene and
Propylene and other hydrocarbon products. Ethylene product will be consumed in the
Ethylene Oxide and Glycol unit. The Ethylene product also will be exported via the
Ethylene Grid to supply Ethylene to Petlin (LDPE unit) and other Ethylene product
consumers (VCM & PEMSB). Propylene product will be consumed in the Butanol
unit and also exported to Petlin. Other products will either be consumed as fuel or
exported. In addition to hydrocarbons, HHP Steam will be generated in the Furnace
TLES to supply most of the steam needs for Olefins, and the excess exported to
Utilities as MP Steam and LP Steam.

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 The basic process of producing Ethylene includes thermal decomposition
(cracking) in the Furnaces, Quenching the cracked gas to remove the heavier
components before Compression, compressing the cracked gas to high pressure to
facilitate the final process of Gas Separation. The major equipment and columns to
produce Ethylene and Propylene are listed below. There are many other heat
exchangers, pumps and smaller processes involved in the overall process to
accommodate the by-products produced from cracking Ethane and Propane.

Steam, Fuel and Electricity are the “big three” utilities necessary to operate the
Olefins Unit. Steam and fuel are generated by Olefins and the majority will be
consumed within the unit with the excess steam and fuel being exported to support
the other units utility needs. Two other processes that are necessary to provide
cooling and condensing for Olefins gas separation are the Ethylene and Propylene
Refrigeration cycles. Both cycles include a compressor and many heat exchangers
and vessels. Olefins will operate a closed Cooling Water cycle necessary for cooling
compressor discharges and other processes. Olefins will operate a BFW ( Boiler
Feedwater ) system which includes a Deaerator, BFW Pumps and a Water Polishing
unit for recycled condensate. Utilities such as Nitrogen, Instrument and Plant Air
and Portable Water will be supplied from CUF through Utilities.

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PROCESS FLOW (HEAVY SEPARATION)

SYSTEM 20

CG PRECOOLER & KO DRUM: CGC discharge is cooled by Propylene

refrigeration and liquids are condensed and separated in the cracked gas before
entering the CG Dryers. Cracked gas is recycled from the KO Drum as “minimum”
flow to the CG Compressor.

CG DRYERS: Moisture in the cracked gas is removed as it passes downward

through the molecular sieves. Dryer sieves become saturated with moisture and
have to be regenerated with hot Tailgas (Hydrogen & Methane going to the fuel gas
system ) frequently.

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SYSTEM 21

HYDROGENATION REACTORS: Dry cracked gas is heated up for

hydrogenation in parallel feed vs effluent exchangers, then a LLP Steam
exchanger. Acetylene is converted to Ethylene. Other secondary conversions occur,
one being CO is converted to Methane and water. A small amount of Green Oil is
created and it and water are separated from the gas in the Green Oil Separator.

SYSTEM 26

DEPROPANIZER: Propylene and Propane are separated from Butadiene and

heavies that go on to the Debutanizer. The C3 overhead goes to the C3 Splitter for
final product separation

SYSTEM 27

C3 SPLITTER: This is the final separation between Propylene and Propane, with
Propy- lene overhead product going to the Propylene Product Storage Tank for
delivery to Petlin and Butanol. Propane is recycled back as Furnace feed after being
vaporized and superheated.

SYSTEM 28

DEBUTANIZER: C4’s, primarily Butadiene is separated from C5’s and heavier,

which are routed to the Gasoline Redistillation Column for further refining. The C4
overhead stream is routed to the Mixed Fuel Gas header and utilized as fuel.

SYSTEM 33

REGENERATION: Tail gas was used to remove moisture accumulated in CG Dryer

bed to ensure the system can operate continuously.

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DAILY ACTIVITIES

In overall, the total number of internship student in Olefins department is 18

persons. All intern were regroup into six team to certify for each area (Furnace,
Quench, Cracked Gas Compressor, Heavy separation, Light separation, Auxiliary)
during our internship period. Before the certification program started, all intern need
to attend new employee orientation (NEO) and new member integration (NMI) in the
first 3 weeks. In both program have include several module, which is a mandatory
for new employee to attend.

NEO modules:-

1. Health, Safety & Environment: Plant safety induction, Hazard

communication
2. Zero Tolerance (ZeTo) rules
3. Permit to Work (PTW) & Job Safety Analysis (JSA)
4. PPE: Respiratory program, Hearing protection, Indoor air quality
5. Plant emergency response
6. Confined Space Entry (CSE)
7. Line & Equipment Opening (LEO)
8. Working at Height (WAH)

NMI modules:-

1. Building tour & introduce to all department members

2. Review organization chart, Mission & Vision
3. Review Team Norm
4. Leader Expectation
5. Department role matrix
6. Conflict resolution (L3 Procedure)
7. Review job description
8. Olefins unit emergency plant
9. Location of safety shower and eyewash stations
10. Operating procedure & Emergency response procedure

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 After all module in NEO & NMI completed, all intern allowed entering the
plant area with proper wear of personal protective equipment (PPE). Five PPE need
to be wear to enter the plant, which are fire resistance cloth, safety boot, safety glass,
mono-goggles, safety helmet, chemical resistance glove, earplug and earmuff. Given
the authorization, interns need to do line tracing task for each system that have been
assigned. Along with the line-tracing task, interns need to complete training package,
which is a set of question related to the system. These task need to be completed
around 1.5 month started from 17 March until 5 May. During the period, all intern
need to familiarize with the environment and working condition inside the plant.
Interns also can gain new knowledge by following the operator do their routine daily
checklist and equipment basic care. These are several knowledge that we gain during
line tracing session.

1. Linde manual- Describe about the process description, process

parameter, startup & shut down system
2. P&ID for each system- trace the process pipeline which are hydrocarbon
process line, flare line, utilities line (steam, nitrogen, service water, plant
air), pressure safety valve line
3. Operating procedure- shows the steps to operate equipment
ex: Switching and startup reflux pump, Preparation of equipment for
maintenance
4. Operational Safety Standard (OSS) and Critical Operating Parameter
(COP) for each equipment in process
5. Location of safety system in plant- Fire alarm box, Deluge valve system,
Gas detector, safety shower & eyewash, Fire hydrant & monitor
6. Simple presentation with technical advisor- update learning progress,
identify level of knowledge in real industry, close gap
7. Instrumentation- indicator, transmitter, controller and element

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 During completing the line-tracing task, a test, which is Operational Safety
Standard (OSS) and Critical Operating Parameter (COP), have been conducted.
There are 20 question in total for the test, which are 10 OSS & 10 COP. Passing
mark for this test is 100% and if failed intern need to retake the test. This test is
important to evaluate level of awareness about process & occupational safety and
hazard that may occur in plant.

After all intern have finish line tracing, performance test will be conducted by
process operator to evaluate the line tracing progress. This evaluation session start
from 24 April until 5 March. During this test, interns need to answer some question
in front of the operator inside the plant. These are some question asked by the
operator.

1. Location of control valve and hand valve for heavy separation area
2. Operating procedure for operate equipment
- Switching pump
- Preparation of equipment for maintenance of pump
- Warm up reactor
3. Location and function of utilities station
4. Location of deluge valve system and step to reset
5. Process flow all system
6. Identify isolation valve for hydrogenation reactor
7. Locate all chemical injection pump

Question that fail to be explain or answer will be taken as an action item after the
test. Interns will need to close the gap by meeting with engineer or boardman. The
action item question will be ask again during final presentation. This is to ensure that
the knowledge that we gain from the close gap session is correct.

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 Once performance test passed, interns will proceed to next evaluation, which is
area certification test. This test was conducted to evaluate the level of understanding
about the process occur in each system in the assigned area. The total question for
each area is different and the passing mark is 80%. Interns that fail to pass the
passing mark need to retake the area test again.

After passing the area certification test, intern need to proceed to the last task
which is final presentation. We need to prepare ourselves including these
knowledge:-

1. Operation safety standard for critical equipment for the system

2. Critical operating procedure related to our area
- Normal operating limit (NOL)
- Maximum NOL
- Maximum never exceed limit
3. Draw process flow diagram of each system for our area
4. Explain process flow, function of equipment, function valve
5. Operating procedure (OP) related to our system
6. Sample point location

Any question that cannot be answered during final presentation will turn into
action item. This action item must be completed within a week after final
presentation. All the information related to the question can be asked directly to
control room boardman or process engineer. The total mark from all the test and task
given will be as a bench mark for interns to be selected as a contract staff. Interns
that was selected will have an opportunity to join the major turnaround of Olefins
plant, which start from 18 August until 2 October.

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TASK ASSIGNED

Task Duration

New employee orientation 17 February – 28 February

New member integration 5 March – 9 March

Line tracing 17 March - 5 May

Area certification test 2 April

Operational safety standard (OSS) & 9 April

Critical operating parameter (COP) test

Turnaround workshop 22 April - 23 April

Performance test 24 April – 5 May

Final presentation 6 May – 16 May

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CONCLUSION

Author has a great opportunity having an internship programme in Petronas

Chemical Olefins Sdn. Bhd. Besides the experience gained during 14 weeks, it has
widened up his mind on real working environment. One of the most memorable
moments are bonding expressed by the staff that describes the culture in the
company. The author also got a chance to join some other programme for example;
intersport house, a talk during Majlis Tilawah Al-Quran etc. The staffs treat the new
comer as a real operator.

The author also fully satisfied to be a trainee in Petronas Chemical Olefins

Sdn. Bhd. because can learn and exposed to steps of becoming an Engineer
theoretically and practically. Other than having good time being here, all the
objectives of the industrial training has been fulfilled completed.

This industrial internship also has broadened the knowledge and helps the
author to understand the real process that took place in the plant. The author was able
to see the equipment’s used in the plant and how optimization is applied in the whole
process. The experience and knowledge will surely help the author when graduating
from University Teknologi Mara (UiTM) Cawangan Terengganu, Kampus Bukit
Besi for completion in Diploma Chemical Engineering.

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