UNIVERITI TEKNOLOGI MALAYSIA
SCHOOL OF ELECTRICAL ENGINEERING,
FACULTY OF ENGINEERING
INDUSTRIAL TRAINING REPORT
BY
MUHAMMAD FARHAN BIN MOHAMMAD RUSHDI (A19EE0093)
2021/2022
BACHELOR OF ELECTRICAL ENGINEERING
TRAINING PLACE
: EXEN International Sdn Bhd
East Coast Design Office
Lot 50081-50082, Level 1, Kg Baru Kerteh
Jalan Kemaman-Dungun
24300 Kerteh
Kemaman, Terengganu
MALAYSIA
TRAINING PERIOD
: 24 JULY 2022 – 14 OCTOBER 2022
COMPANY SUPERVISOR : MOHD SYAWALUDIN NOR AL-DIN
FACULTY SUPERVISOR
: PROF. MADYA DR. MOHAMAD SHUKRI
REPORT DATE
: 19/10/2022
ii
ACKNOWLEDGEMENT
I would like to express my gratitude to several people from Exen
International Sdn Bhd for guiding me throughout the whole practical training period
from 24 July 2022 until 13 October 2022. This project can be done successfully
because of their help and support all the times especially when I am facing
difficulties.
Firstly. I would like to thanks to my faculty supervisor, Prof. Madya Dr.
Mohamad Shukri who was always there whenever I need help. Although he always
busy with his own commitment, but he still willing to provide me guidance and
advices to solve my questions and doubts during my internship period.
Secondly, I would like to thanks to my company supervisor, Mr. Mohd
Syawaludin Nor Al-din (Senior Engineer) who has been guiding me since my first
day undergoes industrial practical at Exen International Sdn. Bhd. He is willing to
share his own experience such as electrical engineering knowledge and regarding
latest electrical engineering knowledge and company operation. He has also
sacrificed his time for me in to guide me in my daily job tasks from the beginning of
the internship until the end of the program.
Finally, I would like to thanks to my parents and family members who are
always keep spiritual support and financials support for me while doing this
internship. They always encourage me when I faced any problems and motivate me
not to easily give up till, I complete this internship successfully.
iii
ABSTRACT
An internship can provide a student with professional work experience in a safe
and structural environment with guidance from experts. Internship help students to
master professional skills such as communication, responsibility and technical skills
that might be useful in future career. This report provides the details of the 12 weeks
internship at Exen International Sdn. Bhd, Kerteh, Terengganu. I was assigned as an
internship trainee at Electrical team under the company supervisor, Mr. Mohd
Syawaludin Nor Al-din and my faculty supervisor Dr Prof. Madya Dr. Mohamad
Shukri. During the industrial training, the assignment given include various kinds of
job tasks related to Electrical Engineering. One of the vital tasks given is Basic
Engineering Design For Storage And Handling Facilities For Propylene Oxide And
Ethylene Oxide. A JV company between PCC & PETRONAS have planned study to
setup an Oxyalkylates facility at PVC plot area inside the former VC(M)SB plant in
Kertih, Terengganu. The new plant will produce Etoxylates and Polyols. The project
required a good understanding of AutoCAD, DIALux and ETAP.
iv
TABLE OF CONTENT
CHAPTER
1
2
3
TITLE
PAGE
ACKNOWLEDGEMENT
ii
ABSTRACT
iii
TABLE OF CONTENT
iv
INTRODUCTION
1
1.1
Introduction of Exen International Sdn. Bhd.
1
1.1.1
Quality Statement
2
1.1.2
Products and Services
3
1.2
Organisation Structure
4
1.3
Conclusion
4
PROVISION OF TRAINING
5
2.1
Introduction
5
2.2
Part of Project
5
2.3
Software
6
BED FOR STORAGE AND HANDLING FACILITIES 7
FOR PROPYLENE OXIDE AND ETHYLENE OXIDE
3.1
Project Background
7
3.2
Objective
8
3.3
Methodology
8
3.3.1
Current Carrying Capacity
9
3.3.2
Voltage Drop
10
v
3.4
3.5
4
3.3.3
Short Circuit Current Carrying Capacity
10
3.3.4
Loadlist Formula
11
Result
12
3.4.1
Loadlist
12
3.4.2
Cable Sizing
12
3.4.3
Cost Estimation
13
Conclusions
13
Conclusion
14
4.1
Introduction
14
4.2
Overall Achievement
14
4.3
Problems
15
4.4
Opinion and Suggestion
15
4.5
Conclusion
15
DECLARATION FORM
16
1
CHAPTER 1
INTRODUCTION
1.1
Introduction of Exen International Sdn. Bhd.
Exen history dated back from 2011, where it have established into EXEN
International Sdn Bhd (EXEN) and have demonstrate itself as one of the main
service provider in covering diverse services and businesses in energy sector. Exen
industry focus includes Oil & Gas (upstream and downstream), Petrochemical
Industries, Renewable Energy and Energy Efficiency, with dozens of experiences in
retrofitting and brownfield services.
Embarking on Engineering Procurement Construction Management
(EPCM) and Engineering Procurement Construction and Commissioning (EPCC)
approach, EXEN have a proven track records on managing contract starting from
proposal stage to conceptual studies and up until construction and commissioning.
Exen in-house services cover multidisciplinary engineering, including
technical department of Civil & Structural, Mechanical & Piping, Instrumentation &
Control, Electrical and Process & Process Safety. The non-technical department
covers Procurement and Sourcing department.
Applying an agile method on current exciting industry landscape, Exen
technical team of engineers and designers are trained to adapt constant challenges,
and technically have proven over time we are able to grasp or at least be parallel to
what the industry required. Plant optimization, rejuvenation projects, fitness for
service and life extension of equipment have been our core services to customers,
worldwide.
2
1.1.1
Quality Statement
Exen can customize a normally redundant/overlapping scope of E&I, Fire
Safety and Process Safety in small EPCC package covering this end-to-end services:
•
Development of front-end including E&I system customization, field
rejuvenation and retrofitting, fire suppression sizing and general
arrangement, selection of detectors, requirement for hose reel and fire
watch, complete with material take-off for EPCC
•
Development of customized datasheet and specification.
•
Development of complete FGS system architecture covering from
understand existing tie-ins up until new detectors coverage with our inhouse FGS Mapping identifications software
•
Certified HAZOP/HAZID and SIL facilitator for any projects scope
focusing to optimized scope within main contractor’s EPCC scope with
safety aspects in place
•
In-house Procurement and sourcing department, construction and
commissioning team for E&I equipment, Fire Safety and FGS equipment
works
•
Propose design and build solutions inline with BOMBA certifications and
approval, as well with liaison with regulatory approval of Majlis
Perbandaran (City Council) and other regulatory bodies
•
Exen EPCC package and integration for E&I and fire safety include with
Exen In-house product line up and customization to client needs including
Autronica, Weidmuller, Honeywell Detectors and Drager and certified
with international certification of TUV, BS, NFPA,SIRIM and BOMBA
among others
•
Portable and permanent detector calibration services for turnaround
3
1.1.2
Products and Services
Exen International provides various engineering services to fulfil client’s
needs and requirements. They are committed to deliver professional services to their
customers especially manufacturing industries.
MULTI-DISCIPLINES ENGINEERING, EPCC & EPCM SUPPORT
•
•
•
•
•
•
•
•
•
Pre-Conceptual and Economic Study for Development Project
Project Management and Consultancy (PMC)
Conceptual/ Feasibility Studies & Basic Engineering Design
Front End Engineering Design (FEED)
Detailed Design Engineering (DDE)
Procurement Support
Follow-On Engineering
Construction Support Engineering
Commissioning Support
MULTIDISCIPLINARY ENGINEERING DESIGN
•
•
•
•
•
•
•
•
•
•
Process and Process Safety Engineering Electrical Department
Civil and Structural Engineering
Electrical Engineering
Instrumentation and Control Engineering
Mechanical Engineering
Piping Engineering
Renewable and New Energy Engineering
Asset Life Extension and Asset Management
Procurement and Contract Sourcing for EPCC
Construction and Commissioning Support
4
1.2
Organisation Structure
Figure 1.1 below the current organization chart for Exen International
Sdn. Bhd. It consists of 6 main departments which are Project
Management, Process and Process Safety, Mechanical and Piping, Civil
and Structure, Electrical Power and Instrumentation and Control.
Figure 1.1 Exen International Sdn. Bhd. Organisation Structure
1.3
Conclusions
This chapter has introduced about the background history and
organization structure of the company where the training took place for 12 weeks of
industrial training.
5
CHAPTER 2
PROVISION OF TRAINING
2.1
Introduction
This chapter will discuss on all parts of project in general that has been
done during the 12 weeks of industrial training. This will include a explanation of a
software that has been used to complete the project.
2.2
Part of the Project
The project that I have been taken part is Basic Engineering Design For
Storage And Handling Facilities For Propylene Oxide And Ethylene Oxide. So the
task that I need to do is to calculate the loadlist, cable sizing and cost estimation.
In general for loadlist is The new load and power consumption for release hook is
based on input from mechanical discipline and vendor data. Existing load is based on
LV Single Line Diagram, LV-MCC2 PHASE 2 (KCTF2-E-5-0101). Some load not
mention in existing SLD is assumed based on breaker utilisation rating only.
6
For sizing of cables, the following a specification shall be taken into
consideration:
•
Cable continuous current carrying capacity
•
Voltage drops during steady state operation
•
Cable short circuit thermal capability
•
Design ambient temperature
•
Installation methods
2.3
Software
The software that has been used for my internship is AutoCAD, ETAP
and DIALux. AutoCAD is use for the design drawings such as schematic diagram
and one line diagram. ETAP is used for simulation and modelling software tool for
electrical power engineer to calculate load in the diagram. DIALux is used to
calculate the lamp and lux needed to be in a certain area.
7
CHAPTER 3
BASIC ENGINEERING DESIGN FOR STORAGE AND HANDLING
FACILITIES FOR PROPYLENE OXIDE AND ETHYLENE OXIDE
3.1
Project Background
A JV company between PCC & PETRONAS have planned study to setup
an Oxyalkylates facility at PVC plot area inside the former VC(M)SB plant in
Kertih, Terengganu. The new plant will produce Etoxylates and Polyols.
Kertih Terminal Sdn Bhd. (KTSB) have been invited to participate in the
feasibility study to provide the following:
(a) New Storage Tank (API 620) and handling facilities for Propylene Oxide
(PO) based on the following requirement: •
Pipeline for jetty (Berth B2b) to KTSB’s Terminal tank for ship
unloading, vent/ vapour line from tank back to jetty.
•
Pipeline from KTSB’s Terminal tank, passing through Terminal Piperack,
Row 2 and Row 3 to PCC-OM BL.
8
(b) Pipeline for Ethylene Oxide (EO) from PCOGD BL, passing through
Terminal Piperack, Row 2 and Row 3 to PCC-OM BL.
3.2
Objective
The objective for this project is:
•
To design the new storage facilities for PROPYLENE OXIDE and
ETHYLENE OXIDE
•
To design handling procedures for PROPYLENE OXIDE and ETHYLENE
OXIDE
•
3.3
To calculate the cost estimation for the project.
Methodology
This project needs to be done by all engineers from the different
department. For Electrical engineers we need to make a basic engineering design for
storage and handling facilities. First we need to make a design basis for a project to
make as a reference to other parts of the needed to be done.
Second, we need to make a design for the project using AutoCAD and
refer to the original plan for a wiring system. After that do a site visit to look at the
9
place to do the design and measure the range and record the specification for the
already exist electrical equipment. Redesign the drawing and calculate the cable
sizing needed for the tank. Also calculate the loadlist to make sure the power is
enough for all the already exist and new equipment that will be put in.
As consultant, we also look at the price and type of the equipment that is
suitable for the tank and the place that will be build at. Also calculate the lux to make
sure all the place have enough lux level. The lux is based on the required from the
guidelines.
For a cable sizing we use a formula as below:
3.3.1 Current Carrying Capacity
In sizing a cable, the continuous site rated current of the cable must be higher than load
current and the trip setting of protective devices. Where IL is load current, ICSR is cable site
rated current and IBR is breaker rating currents, therefore
ICSR > IL,
IBR >IL,
ICSR > IBR
So, ICSR > IBR > IL
The cable site rated current, ICSR = ICR x K1 x K2 (for 3 Ø and DC system)
Where,
ICR
K1
K2
-
IL
= P x 1000
3 x Vn x p.f. x 
(for 3 Ø AC system)
IL
=
P x 1000
Vn x p.f. x 
(for 1 Ø AC system)
IL
=
P x 1000
Vn
Where,
IL
Vn
P
p.f.

-
cable rated current
temperature correction factor
group derating factor the load current,
Load current (A)
Nominal voltage (V)
Load (kW)
Power factor
Efficiency at full load in p.u.
(for DC system)
10
3.3.2 Voltage Drop
Voltage drop is calculated by the following formula:
VD
= 3 IL x (Rc Cos  + XC Sin ) x L
N
(for 3 Ø AC system)
VD(%) = VD x 100
Vn
VD
= 2 IL x (Rc Cos  + XC Sin ) x L
N
(for 1 Ø AC system)
VD(%) = VD x 100
Vn
VD
= 2 IL x Rc x L
N
(for DC system)
VD(%) = VD x 100
Vn
Where,
VD
Voltage Drop (v)
Cos  Power Factor (p.f)
Rc
Cable Resistance (ohms/km)
XC
Cable Reactance (ohms/km)
L
Estimated Cable Length (km)
N
Number of runs in parallel connection
Vn
Nominal Voltage
3.3.3 Short Circuit Current Carrying Capacity
Short circuit current carrying capacity is assessed from the following formula. Cable is
XLPE insulated, copper conductor cable.
A
I=
224
t
A
ln(230 +  1 / 230 +  0)
= 143
t
Where,
A
I
t
1
0
=
=
=
Cross sectional area of the conductor (mm2)
Short circuit current (A)
Total fault clearance time (seconds)
=
Maximum permissible temperature at short circuit 250 0C
=
Max. permissible continuous operating temp. 90 0C
11
For a loadlist we use formula such as:
3.3.4 Loadlist Formula
Load Factor
=
Absorbed Load (kW)
Motor Rating (kW)
Operating Real Power, P
=
Absorbed (kW)
Efficiency
Operating Reactive Power,Q
=
Operating kW x tan θ
kVar
=
Reactive power in kilovolt-amperes reactive
kW
=
Real power in kilowatts
Cos θ
Apparent
Power
= factor of the load
Power,
S
in =
√ (kW2 +kVAR2)
kilovolts-ampere (kVA)
∑ Continuous kW + 0.3 ∑ Intermittent kW
Maximum Normal Running =
Plant Load
(or single largest intermittent load, whichever is larger)
Peak Load
=
∑ Continuous kW + 0.3 ∑ Intermittent kW
(or single largest intermittent load, whichever is larger) +
0.1 ∑ Standby kW (or single largest standby load,
whichever is larger)
Firm Capacity of Electrical
Supply Required
= Minimum Installed Power Supply Required 125% of
Peak Load
For the last part, we need to make a cost estimation for all the equipment
and labour needed for the project.
12
3.4
Result
The result for this project is we obtain all the value and the cost estimation
needed to further the project for the contractor that will continue the project.
The result for the loadlist, cable sizing and cost estimation is been shown
and presented as below:
3.4.1 Loadlist
3.4.2 Cable Sizing
13
3.4.3 Cost Estimation
3.5
Conclusions
In this chapter, the information detail for the industrial training at EXEN
has been learn. This project is only for the planning for the future reference. The
consultant job is mostly just do a studies toward all the things that might affect the
real project. This chapter also show all the result of all the calculations.
14
CHAPTER 4
CONCLUSION
4.1
Introduction
In this chapter, the overall achievements that have gained during the
industrial training will be conclude. The problems and suggestions will also be
discussed in this chapter.
4.2
Overall Achievement
Industrial training program gives an opportunity for students to experience
real working environment in related industry. Throughout 12 weeks industrial
training at Exen International Sdn. Bhd. The internship provides a lot of new
knowledge and working experience especially in Consultancy of Electrical
Engineering related to oil and gas industry.
At the beginning of industrial training, Exen gives training on related software
used by company such AutoCAD, ETAP and DIALux. These is to enhance technical
skills to ensure that upcoming work tasks able to execute smoothly.
Finally, the internship enables the achievement of good soft skill. There are
several opportunities given during the internship such as to visit clients’ site to learn
more about the work environment.
15
4.3
Problems
Overall, there are no any issues or difficulties from working environment
and hardware provided by internship company such as working space,
communication tools, laptop and software needed.
However, throughout all the job tasks given during internship period,
several problems occur which include understanding the problem statements of tasks
given, getting familiar with hardware and software. Moreover, there might be
situation where the error that appears does not have clear guideline or solution
during troubleshooting. Execution might get even worst when needed to compete
with time constraint.
Thus, a lot of studies and practices needed to enhance the technical skills
required to execute these job tasks. Through the guidance and advices from
supervisor and colleagues, all the tasks given managed to execute smoothly as
planned.
4.4
Opinion and Suggestion
As a trainee, it would be easier for student if university able to have a
close collaboration with listed Electrical Engineering company or organization to
provide or offer an internship opportunity. Through close collaboration, job/task
scope can be clearly identified. Hence, university can offer related courses or
workshops to enhance student technical skills such as Circuit Design and
technologies used. So, student would not be facing any issues on selecting their
desire path.
4.5
Conclusion
Students are highly encouraged to undergo industrial training at Exen
International Sdn. Bhd. This is because the operation of this organization involved
with oil and gas field. In addition, there are many new experiences able to expose
that hardly to get while in university.
16
DECLARATION OF THE UNDERGRADUATE INDUSTRIAL TRAINING
REPORT AND COPYRIGHT
Trainee full name
: Muhammad Farhan Bin Mohammad Rushdi
Date of Birth
: 11/09/2000
Title
: Industrial Training Report
Academic Session
: 2021/2022 3
Date
: 19/10/2022
I declare that this industrial training report is classified as:
✓
CONFIDENTIAL
(Contains confidential information under the
Official Secret Act 1972)*
RESTRICTED
(Contains restricted information as specified by
the organization where research was done)*
INTERNAL
I agree that the industrial training report is for
internal only
1. I acknowledged that Universiti Teknologi Malaysia reserves the right as
follows:
2. The industrial training report is the property of Universiti Teknologi Malaysia.
3. The School of Electrical Engineering has the right to make copies for the
purpose of reference only.
Certified by:
Verified by:
INDUSTRY SUPERVISOR
SCHOOL SUPERVISOR
SIGNATURE
SIGNATURE AND STAMP
Date: 20/10/2022
Date: