INDUSTRIAL TRAINING REPORT

PEER MARK ENGINEERING

SDN. BHD.

FALIQ BIN AJIR

REPORT SUBMITTED IN PARTIAL FULFILLMENT

FOR THE DIPLOMA IN ENGINEERING TECHNOLOGY
(WELDING TECHNOLOGY)

DEPARTMENT OF WELDING TECHNOLOGY

UNIVERSITY KUALA LUMPUR-MALAYSIA FRANCE INSTITUTE
BANDAR BARU BANGI

2012
 INDUSTRIAL TRAINING REPORT
PEER MARK ENGINEERING
SDN. BHD.

FALIQ BIN AJIR

REPORT SUBMITTED IN PARTIAL FULFILLMENT

FOR THE DIPLOMA IN ENGINEERING TECHNOLOGY
(WELDING TECHNOLOGY)

DEPARTMENT OF WELDING TECHNOLOGY

UNIVERSITY KUALA LUMPUR-MALAYSIA FRANCE INSTITUTE
BANDAR BARU BANGI

2012

i
 DECLARATION

I declare that all parts of this report are the result of my own work except the

Quotations and the references, the sources of which have been acknowledged in the

bibliography.

…………………… .
2012 FALIQ BIN AJIR

ii
 SIGNATURE PAGE

This report was read and verified by:

………………………..

(RAVI CHANAN) DATE:

Company Supervisors

………………………..

(DR. MOHAMMAD NOOR WAHAB) DATE:

Lecturer Supervisors
 ACKNOWLEDGEMENT

Assalamualaikum w.b.t.

“Alhamdulillah”, That is how I describe about the industrial training opportunity.

I would like to thank the company that have given me the opportunity to learn more about

the industry that is PEER MAR ENGINEEERING Sdn Bhd . During the training I was

nurtured and spoon fed with a pool of knowledge that are very valuable. The company

have thought how the real working environment are , they are so gallant that they trust

me by handing me a real job , which turn out to be really valuable experience. Special

thanks to company managers especially Mr. Ravi Chanan and Mr. Maswandy who guide

and assigned me with task and Mr. Shamsul Abbas who really help me a lot and teach

many things about the industry and very supportive , and to Mr Ruzaidi and Mr. Zahir

who help me and my friend whenever we have problems with our work , support and

help me in completing this program successfully and also the owner of the company Mr.

Marcus who gives us the opportunity to work with the company. Thanks for guiding and

helping me in learning and gaining knowledge in oil and gas industrial career.

Not to forget for all other workers because giving me a good cooperation and

made me as one of the PEER MARK ENGINEERING family. Hope that PEER MARK

ENGINEERING Sdn. Bhd. will continue its growth and be success in future and

recognize in locally and also internationally.

iii
 ABSTRACT

The report is divided into two sections, Economic Section and Technical Section.
The Economic Section contains the company background and profile of PEER MARK
ENGINEERING SDN. BHD .The company is specialize in design and manufacturing of
process modules , heat transfer equipment , pressure vessels , process column and other
equipment for oil and gas , petrochemical , power plant and general industries . The
product is marketed locally and worldwide. In the technical section, the trainee was given
a project to complete during industrial training. The project is Provision of Computer
Assisted Operations (CAO) at ANGSI-B. As a trainee I was assigned as a Quality Control
Inspector of the project who represents PEER MARK ENGINEERING. From the project,
the trainee has gained valuable working experience and managed to complete the
industrial training report.

iv
 TABLE OF CONTENTS

Declaration…………………………………………………………………………… ii

Signature page…………………………………………………………………………...

Acknowledgement…………………………………………………………………….iii

Abstract…………………..………………………………………………………….. iv

List of Appendices…………………………………………………………………….v

List of Illustrations……………………………………………………………………vi

Chapter 1………………………………………………………………………………1

Chapter 2……………………………………………………………………….……...5

Chapter 3……………………………………..…………….……………..………….. 9

Chapter 4……………………………………………………………………..……… 27

Bibliography……………………………………………………………………………29

Appendices………………………………………………………………………...… 30

Illustrations…………………………………………….………………………………42

v
 LIST OF APPENDICES

Appendix 1………………………………………………………………………………29

Appendix 2……………………………………………………………………………....30

Appendix 3………………………………………………………………………………31

Appendix 4………………………………………………………………………………32

Appendix 5………………………………………………………………………………33

Appendix 6………………………………………………………………………………34

Appendix 7………………………………………………………………………………35

Appendix 8………………………………………………………………………………36

Appendix 9………………………………………………………………………………37

Appendix 10……………………………………………………………………………...38

Appendix 11……………………………………………………………………………...39

Appendix 12……………………………………………………………………………..40

Appendix 13……………………………………………………………………………...41

vi
 LIST OF ILLUSTRATIONS

Illustration 1……………………………………….……………………………………..42

Illustration 2…………………………………………….…….………………………….43

Illustration 3…………………………………………………..…….……………………44

Illustration 4……………………………………………………….……………………..45

Illustration 5……………………………………………………………………………...46

Illustration 6………………………………………………………………...……………47

Illustration 7……………………………………………………………...………………48

Illustration 8……………………………………………………………..………………49

Illustration 9……………………………………………………………………………..50

Illustration 10……………………………………………………………………..……..51

vii
CHAPTER I

INTRODUCTION
 CHAPTER I
(INTRODUCTION)

General Introduction and Overview of training

Industrial Training (INTRA) is an informal training done is in real situation like in a

company. Industrial Training also is compulsory to all MFI full time students since it is

one of criteria for graduation. Trainee needed to complete their INTRA in 16 weeks, upon

which a report is submitted to the assigned supervisor in MFI. Students also need to make

a presentation regarding their training to the panel members who are lectures from the

respective technical department. Marks will be given after evaluating the student. The

industrial training itself cover four credit hours.

OBJECTIVES OF THE INDUSTRIAL TRAINING
1
Definition

An informal training done work in area situation, and in the last semester at real working

condition area, such as in industrial company or for an industrial project which to be done

in Malaysian France institute and the industrial training much have constraints and they

should be able to solve that the to get good result of training.

The objective of the training in the Industrial environment is to develop the autonomy,

responsibility and creativity of the students.

 To understand to company in the item of function and procedure

following the Code and Standard.

 Work in real environment, which is different from the training

environment.

 To develop the autonomy, creativity and responsibility to student.

 Be part of the professional team in order to measure the human resources

importance.

 To apply all knowledge gain in MFI to the reality of working.

 To make student prepares himself to work in a real working environment.

 To perform a good performance which may offers a permanent position or

a recommendation to student.

2
INDUSTRIAL TRAINING LOCATION

The industrial training was done at the PEER MARK ENGINEERING SDN. BHD. The company is
located at Lot 8965 , Jalan Udang Galah , TELOK GONG, PORT KLANG. The address of the
company is:

Figure : Location of Peer Mark Engineering Sdn Bhd.

TRAINEE IN PEER MARK ENGINEERING

The position that was given to the trainee is the Q.C (quality control). The trainee was

assigned for 2 months at the QC department and 2 more months at Production

department. The Q.C is responsible to check the quality of the product , quantity ,

material handling , visual inspection , fit-up inspection , dimensioning , final

dimensioning , Non-Destructive examination request , Radiographic test request , consult

with client , organize Welder Qualification Test (WQT) , organize Hydrostatic test and

many more. The task of QC inspector is to make sure that the task will go on progress

without any problems.. The Company supervisor is the person that entirely responsible of

the trainee progress. He will give the entire task to the trainee. The industrial Training

took 16 weeks starting from 19th December 2011 and end on 7th April 2012.

3
Working Schedule

1. Time of work
 At 8.30 a.m. until 5.30 p.m.
 On Saturday work at 8.30 a.m. until 1.00 p.m.
 Overtime (OT) is recommended if there is many work.
 Every Monday need to come early at 8.00 a.m to attend Tool Box
Meeting.
 Breakfast for 30 minutes at 10 a.m to 10.30 a.m
 Lunch break for 1 hour at 12 p.m to 1 p.m
 There is also break at 3 p.m for 30 minutes
 Overtime (OT) will start on 5.30 p.m an onwards.
Basically as a trainee we are encouraged to do overtime to help with the
work because there is not enough man power in Peer Mark Engineering.

2. Allowance
 Allowance will be pay as follow :
 Basic allowance RM600.00
 OT allowance RM100.00
 Total RM700.00

4
 CHAPTER II

GENERAL PRESENTATION OF COMPANY

 CHAPTER 11

GENERAL PRESENTATION OF PEER MARK ENGINEERING

COMPANY PROFILE

1. Company Name : PEER MARK ENGINEERING SDN. BHD.

Lot 8965 ,
2. Address : Jalan Udang Galah,
Telok Gong,
42000 Port Klang
Selangor Darul Ehsan.
.

3. Date Incorporate : 30th July 2001

4. Company Reg. Number : 554866-H

5. Share Equity : Non-Bumiputera

6. Paid - up Capital : RM 1,000,000.00

7. Authorized Capital : RM 1,000,000.00

8. Nature of Business : Specialize in Oil and Gas manufacturing.

- Pressure Vessel
- Heat Transfer Equipment
- Process Module
- Process Column

9. BOARD OF DIRECTORS : a) Managing Director

MARCUS CHEW NGEE CHENG

b) Operations and Purchasing

YONG YIP POOI

Accounts and Administration Executive

LOONG MAY YOONG / HOO KAN SEEK

5
10. Organization Chart : (Refer Appendix 1)

11. Company Auditor : LLT & PARTNERS PUBLIC ACCOUNTANT.

No.: 29-A , 1st Floor ,
Jalan SS 2/67,
47300 Petaling Jaya,
Selangor Darul Ehsan

12. Company Secretary : GENESIS PROFESSIONAL SERVICES Sdn. Bhd.

No.: 29-A , 1st Floor ,
Jalan SS 2/67,
47300 Petaling Jaya,
Selangor Darul Ehsan.

13. Bank : AMBANK (M) BERHAD &

STANDARD CHARTERED BANK

14. Built- up area : a) Total Land Area for Plant 1

68,000 sq.ft.

b) Covered Area for Plant 1

60,000 sq.ft.

c) Total Land Area for Plant 2

79,200 sq.ft.

d) Covered Area for Plant 2

47,520 sq.ft.

15. Telephone Number : 603-31343881/603-31343884

16. Fax Number : 603-31341389

17. E-mail : sales@peer-mark.com

18. URL : www.peer-mark.com

6
COMPANY PROFILE

PEER MARK ENGINEERING SDN BHD (PME)

The company was incorporated on 30th July 2001 and was formed by a group of
dedicated and well recognized leaders with more than twenty (20) year of experience in
the field of various mechanical fabrication and project management. They are committed
in terms of quality and integrity through an in house quality plan and meet timely
delivery schedules and customer satisfaction as our company’s policy.

The Company has been accredited by ASME with ASME “U” Stamp, ASME “U2”
Stamp, “R” Stamp and National Board Registration. They are now also working on
developing ISO 9002 Standard to integrate strength and conscientious attitude to gain a
solid reputation in oil and gas industry. Our team of professionals are fully conversant
with international standards as well as practices on all design codes. With the support
of the latest technology of equipment and softwares, we provide unique & precise
engineering solutions to cater to the specific demands of the industry throughout the
region.

The fabrication yard, which situated in Port Klang has made us a preferred fabricator
for process skid modules as well as oversized equipment serving the Oil & Gas,
Petrochemical, Power Plant and general industries regional. We have successfully
supplied equipment and packages to multi-national and local companies in the country as
well as end users in Thailand, Vietnam, Myanmar, Indonesia, Brunei, Philippines, India,
Oman, Qatar and etc.

As an organization that committed to customers satisfaction, quality of products and

meeting the assigned delivery schedule; and with our enhanced HSE policy as well as the
QMS & EMS, we aspire to stay as the leading engineering company to create a
brighter future.

7
CORPORATE LOGO

PARTNERS AND ASSOCIATES COMPANY

 METAL ONE ENGINEERING

METAL ONE ENGINEERING SDN. BHD. A close associates company of PEER
MARK ENGINEERING SDN. BHD. Ménage by a group of experienced
professionals with more than twenty (20) years of experience in engineering of
pressurized equipment and licensed by the Department of Occupational Safety
and Health (DOSH) under the Minister of Human Resources , Malaysia

VISION AND MISSION

To inculcate and strive for quality culture at all level operations . As a quantitative
measure of quality achievement, it is targeted that the reject weld defect through
radiographic examination to be less than 3% per total number of radiographic film taken
per year. The company also target to minimized customer complaints rate , not more than
2 cases complaints per project and a minimum (one) training programs to relevant staff
per year. To continue foster good relationship with customers , the following target is set
that the overall customer satisfaction index shall be greater than (70%) . Responsibility
for quality rest with every employee. However , it is recognized that the management is
responsible to provide the leadership and resources necessary to ensure at all times that
our products and services meet the highest standards on Productivity , Quality ,
Reliability and Safety (PQRS) . This is the fundamental of the company business.

COMPANY EXPERIENCE
(Refer Appendix 13)

8
 CHAPTER III

Provision of Computer Assisted Operations (CAO) at

ANGSI-B
 CHAPTER III

(REPORT ON PROJECT)

ROLE OF QC DEPARTMENT

 Inspect Material
 Fit-up inspection
 Visual Inspection
 Entertain Client and inspector
 Request for Non Destructive Examination
 Identify joint that needed for Radiographic test
 Documentation of Manufacturing Data Record (MDR)
 Ensuring that the correct welding procedure specification (WPS) are being
applied by production department and welders are qualified to perform the
intended work.
 Any other responsibilities as stated in the ASME.
 Ensure that all procedure and the project is met with ASME Code .

EXPECTATION OF THE COMPANY TO QC DEPARTMENT

 QC department is the most important department in Oil And Gas industry.

In Peer Mark Engineering , almost all the documentation and work are
done by the QC department .The company have high expectation on QC
department as it is the backbone of the business. It is important because
Quality is the highest priority for a client. Furthermore if the product has
the highest quality it will also affect the safety of the product. QC
inspectors are tasked to ensure that all the work that has been done in the
workshop has the highest quality based on ASME qualification and Client
spec. For example Petronas has its own Client Specifications where every

9
 manufacturer company has to follow strictly. This is to ensure the quality
of the product at its best.

INTRODUCTION OF PROJECT ASSESSMENT

The project is Provision of Computer Assisted Operations (CAO) at ANGSI-B . Sub-

contracted by INTEGRITY ENGINEERING SERVICES SDN BHD (IESSB) to PEER
MARK ENGINEERING from client PETRONAS CARIGALI SDN BHD (PCSB) .The
project consist of 18 pipe spool with the size of 2" and 11 pipe spool with the size of 3"
and 6" . It also consist of 32 pipe support and few other support. As a trainee I was
assigned as the project QC inspector . I have to meet with the client and do all the QC and
production related work such as material inspection , fit up inspection , Non Destructive
Examination Request and Radiographic Test Request , Painting inspection , Hydrotest
(HT) , complete Manufacturer Data Record , Packing List and Delivery Order.

Name of Project : Provision of Computer Assisted Operations (CAO) at ANGSI-B

Client : Integrity Engineering Services Sdn. Bhd.
Owner : Petronas Carigali Sdn. Bhd.
PROJECT OBJECTIVE TO TRAINEE 10

In our point of view, that objective of this project is to helps us in getting exposed
to the real working experience as a QC inspector and the whole team of
management. Besides increasing our knowledge, we also apply what we have
learnt before in mfi:
 Estimating the materials
 Technical drawings
 Optimizing the material
 Organizing the management board
 Innovating the project
 Listing tools and machines
 Specification of welding types
 Elaborate the procedures of processes
 Estimate the cost
 In terms of mechanics, force, equilibrium, force and other theories
This project totally improves our skills. We get to manage the timeline in-
consistent with the fixed schedule: we would love to try to produce great
products. We also learn how to handle a project and work in a team.

This project can make us;

 To produce a project that can finish in successful and be a role model
to other department or other institution.
 To make us work in order with given time with less supervision.
 To make student in Metal Fabrication and Joining Technology be a
competency and professional. Working as a team.
 To apply what we have learn in MFI.
 To make sure that all the members fully involve in doing the project
and to keep the workmanship and co-operation among the member.
 11

TASK AND RESPONSIBILITY

Based on the project of : Provision of Computer Assisted Operations (CAO) at

ANGSI-B the task are as follows :

 ARRIVAL OF MATERIAL
1. Firstly the material arrive , and as QC inspector trainee have to check the size
the material and the Heat Number so that it is compatible with the ordered
material and check it with mill certificate with the supervision of Client
Representative.
2. After that, use the Heat Number and material type , specification and size to
make a FIT-UP inspection report and Material Inspection Report. All of this
Report needed to be approved by 3 party : manufacturer , client and owner .

 FIT-UP INSPECTION

1. After all the material is clear and get the approval of QC inspector, Store
supervisor (material handler) will give the material to production. Then the
work will be proceed by Production where they will start the fit-up inspection
base on drawings that has been given to the welder by production department.
2. The fit-up inspection will be monitored and approved by QC inspector based
on the design.
3. After fit-up is finish , welding is proceed. Based on the project, the welding
process used is GTAW/SMAW for 3 and ½ inch and more thickness of the
pipe and GTAW for 3 inch and bellow.
4. ( Example of ISO Drawing : Refer Appendix 9).
 12
 WELDING

1. During the welding, QC will make sure that the welder is already qualified and
provided with welder card.
2. Qc will also make sure that the welder used the correct welding process and
position.
3. QC inspector will make visual inspection on the weldment and if its pass the
visual requirement, QC can proceed for Non-Destructive Testing and
Radiographic test.
4. There are 4 welder for this project that use welder number of W016,W057,W022
and W023.
5. For piping is Welder W016 (GTAW/SMAW) and (GTAW) and Welder W057
(GTAW).
6. For Structural is Welder W022 and W023 (SMAW).
7. The welder are qualified and experience welder. There are no problem with
NON-DESTRUCTIVE TESTING after the test are carried out on the weld.
 13
EXAMPLE OF WELDER WPQ FOR THIS PROJECT
 VISUAL INSPECTION 14

Visual inspection is the most extensively used nondestructive examination on

weldments. It is simple and relatively inexpensive, it does not normally require
special equipment, and it give important information is that the inspector must
have good vision. Conscientious visual inspection before, during and after
welding can detect many of the discontinuities that would be found later by more
expensive nondestructive examination methods.

STAGE OF VISUAL INSPECTION

a) PRIOR TO WELDING
After the parts are assemble for welding, the inspector should check the weld
joint for root opening, edge preparation and other feature that might affect the
quality of the weld. The inspector should check the following conditions for
conformity to the applicable specifications.

 Joint preparation, dimensions, and cleanliness

 Clearance dimensions of backing strips, rings or consumable
 Alignment and fit-up of the pieces being welded
 Welding procedures and machine setting
 Specified preheat temperature
 Tack weld quality

b) DURING WELDING
Visual inspection is the primary methods for controlling quality. Some of the
aspects of fabrication that can be checked include the following:

 Treatment of tack weld

 Quality of the root pass and the succeeding weld layers
 Interpass cleaning
 Distortion
 Conformance with the applicable procedure

c) AFTER WELDING
Items that are checks by visual inspection after welding include the following:

 Final weld appearance

 Final weld size
 Extent of welding
 Dimensional accuracy
 Amount of distortion
 Post weld heat treatment
  Repair procedures

15

The figure shows a trainee doing visual inspection on a vessel

 NON-DESTRUCTIVE EXAMINATION
16 (NDE) AND RADIOGRAPHIC TEST
REQUEST

1. In this Project the required NDE is 100% Magnetic Particle Test on all joint
and 100% Radiographic test on all butt joint.
2. QC must keep updated with all the joint that are finished to request the NDE.
MPT must be done first before Radiographic test can be done.
3. The NDE company used for this project is PRESCAN SDN. BHD. (NDE
Report : refer Appendix 2 and 3 )
4. All magnetic particle used in either dry or wet MPI technique shall have good
contrast color against test surface , high permeability . low retentively and
sufficiently fine
5. All areas to be inspected shall be sprayed with coat of white contrast paint of a
thickness not exceeding 24 microns. It could demonstrated with Burmah
Castro field indicator that indications can be detected through the maximum
coating thickness applied.
6. The surface of the part to be tested shall be essentially clean , dry and free of
contaminants such as oil, grease . loose rust, thick paint, welding flux, spatter
or other material that may hinder the movement of iron powder or
interpretation of result indication.
7. MPT used a machine called Yoke to obtain reading.
8. Applied magnetic ink either through aerosol(wet method) or puffer(dry
method) onto the area where magnetic field has been induced with the current
still on.
9. Then observed for indications formed by the magnetic particles.
10. After that cut off current flow before remove the yoke.
11. Then collect the data.
12. For Radiographic test it is running on specified time where there are no person
is working mainly at night. This is for safety reasons.
13. Only NDE personnel shall be on the area during Radiographic testing.
 17
Example of Radiographic Test Report
 HYDROSTATIC TEST 18

1. Hydrostatic test (hydrotest) is a test to determine whether the pipe or vessel is

leak or not. The Pipe or vessel is assemble (connected) and are seal , then are
immersed with water.
2. Water used for hydrostatic testing shall be clean and fresh.
3. All Pressure Gauge and Recorder must have calibration certificate.
4. Hydrostatic test shall be done prior to painting or coating. Hydrotest shall be
performed only after 48 hours of elapsed time form the last welding on pressure
part or support attachment.
5. It Shall be ensured that all foreign matters inside the pipe spool are removed
prior to filling the vessel with water . QC inspector shall carry out a visual
inspection to ensure that dirt , weld spatter or other foreign material are not
present in/on the vessel. Vents shall be provided at all high points of the vessel
in the position in which it is to be tested to purge possible air pockets while the
vessel is being filled.
6. All temporary pipes and connections and blanking devices shall be designed to
withstand the test pressure.
7. For safety reason , the entire area where the hydrotest is carried out shall be
evacuated , sealed-up and adequate warning signboard shall be displayed. Only
authorized personnel shall be allowed in the area of testing. Safety helmet ,
Google and safety shoes are important.
8. After all the NDE are Clear , QC will proceed with hydrotest , the test is
witness by Client and Owner Representative. Before that they will review all
the NDE report and Radiographic Film before the hydrotest can be continued.
9. After Client and Owner Representative is already satisfied with the NDE Report
, Hydrotest for Provision of Computer Assisted Operations (CAO) at ANGSI-B
pipes – 18 of 2 inches pipe spool with pressure of 207 bar and 11 of 3 and 6

19
 inches pipe spool of 153 bar . The Hydrotest specification is based on ASME
B31.3.
10. The metal temperature during the hydrotest shall be maintained at least (17
Celsius) above the minimum design metal temperature but need not exceed (48
Celsius) to minimize the risk of brittle fracture.
11. The Hydrotest were runs on 3 different occasion due to differences of pressure.
12. During the hydrotest the pressure recorder and gauge used is for 10000 psi .
13. The hyrotest step is that the pressure is increase 25% at first , and then it is
increased to 50% for 15 minutes , then it is increased to 75% for another 15
minutes and then it is increase to 100% and is hold for 1 hour . After it is hold
for 1 hour , the pressure is decrease to 75% and then it it slowly decreased until
0% . From the Hydrotest it is showed that there are no leak and the client and
owner representatives are satisfied with the test.
14. The hydrostatic pressure / time data shall be recorded on a certificate , the
report will show the following data (HT chart : refer appendix 4) :
 Hydrostatic test pressure
 Tag no.
 Date of test
 Ambiesnt temperature at time of test
 Pressure gauge no / range and gauge calibration certificate
 Pressure recorder no / range and calibration certificate
The figure shows the pressure recorder is set-up for Hydrostatic Test

20
EXAMPLE OF HYDROSTATIC INSPECTION REPORT
 21

 SURFACE PREPARATION AND PAINTING

1. After all the Pipe Spool are clear of Hydrotest , painting is carried out.
2. Firstly before painting is carried out, the surface must be prepared. The Surface
is prepared by cleaning the surface of the pipe/structure by using blast cleaning.
3. The compressed air supply used for blasted cleaning shall be free from water
and oil. Oil separators and traps shall be provided , installed in coolest part of
the system.
4. All welded area shall be dressed free of slag , weld spatter , scales , shivers ,
unacceptable undercut and other imperfections before blasting.
5. All fabrication, welding and testing should be completed before surface
preparation begins.
6. Blast Cleaning shall be carried out to achieve requirement of client specification
and blast nozzle pressure to be checked before stat to each shift.
7. Blasted surface shall be de-dusted using dry compressed air free of oil traces
before the application point.
8. Blasted surfaces shall be coated within 4 hours after completion of blasting and
while the surface is at the specified standard.
9. Garnet will be used to obtain the required surface cleanliness and anchor
profile.
10. After the Surface is clean , Painting can be carried out.
11. Handling, preparation and application of paint shall be fully agree with the
manufacturer’s recommendations.
12. Painting shall not be applied when temperature of substrate surface is less that
10 Celsius above the dew point of surrounding air or the relative humidity is
greater than 85%.
13. The paint shall applied uniformly to obtain one even coat. Within the DFT
range, free of runs , sags , overspray , dry spray , wrinkling , mud cracking ,

22
 inadequate cure, blisters and with sound adhesion to its substrate or preceding
coat.All runs or sags shall be brushed out immediately
14. Each Coat of paint Shall be allowed to dry for a period of time within the limits
prescribed by paint manufacturer, before over coating. Normally, all Painted
surfaces shall be lightly abraded by emery (sand) paper, prior to over coating.
15. All relevant information and inspection items checked shall duly report in the
blasting and painting report.
16. For ths project there are 2 types of painting system used. System 1A and 5A.
 The painting system 1A has 3 coat. the first coat is BARRIER 77 , 2 nd
coat is DURAMASTIC and the 3rd coat is DURATHANE AS . The
needed DFT microns reading must exceed more than 275. The painting
system is for carbon steel with design temperature equal or less than 110
Celsius. The colour for Support and instrument stand using this system
for the project is YELLOW while Pipe Spool using this painting system
is WHITE.
 The painting 2nd system is System 5A(1) , it has 2 coat . the first coat is
resist 78 and the second coat is SOLVALIT MIDTHERM. The needed
DFT microns reading must exceed more than 135. The painting system
is for Carbon steel with design temperature above 110 Celsius. The
color of the pipe spool painted using this system is White.
 All color of the painting is based on PETRONAS Client Specification.
17. After all the painting is done report of overall work is required. (BLASTING
AND PAINTING REPORT) it is to be inserted in the Manufacturer Data
Record.
 The figure show that the
client checks the painting
system using DFT meter and
a trainee observing surface
preparation and painting at
the painting yard.

 DOCUMENTATION OF MANUFACTURER DATA RECORD (MDR)

23

1. As a QC inspector , we need to compile all the document and data that has been
collect during the fabrication in 1 complete file of Manufacturer Data Record
that will be given to Client 2 weeks after finish of fabrication.
2. All submitted procedure and approved procedure is compulsory and all the
report such as :
 Inspection Test Plan (Refer Appendix 11)
 Approved Procedure
 Material Inspection Report
 Mill Certificate
 Fit-up inspection report
 Dimensional Report
 Welding inspection report (Refer Appendix 8)
 Welder Certificate (Welder Performance Qualification)
 WPS/PQR
 Magnetic Particle Testing report
 Radiographic Test Report
 NDE personnel certificates
 ISO Drawing (Piping and Structure)
 Weld Map
  Hydrostatic test Chart and report (Refer Appendix 4)
 Blasting and Painting report (Refer Appendix 11)
 Inspection Release Note
3. MDR is important because it show all the progress of the fabrication. It is also
act as reference for Client.

24
 PACKING

1. After all the fabrication and painting is finish and already get the approval of
Client representative and the date of the fabrication is almost over , The product
is ready for packing and to be delivered to TERENGGANU and be sent to
OFFSHORE DOCK ANGSI-B.
2. Delivery order and Packing list is made to organize the packing.
3. The product are packed with care so that the quality of the product will remain
intact.
4. Some of the product were put in the box and some are wrapped.
5. After the product is already pack , QC inspector need to entertain Client
representative to witness and make a final inspection on the quality and the
quantity of the product.
6. After Client representative has approved, the product is ready for delivery.
7. The Delivery order needed to get the approval from 3 party that is , the QC
inspector , Client Representative and Logistic Company.

The figure show the box for packing.

The figure show pipe spool is packed.

25
Other On Going Job
Instead of Provision of Computer Assisted Operations (CAO) at ANGSI-B , there are also
other On-Going job in Peer Mark Engineering such as :

1. KBB Northern Hub Project , Client – KROHNE Oil and Gas

2. Hijau Gas Oil , Client –Valsser Engineering
3. GLNG , Client – Kenchana BestWide Engineering
4. Provision of gas jet pump application for ANGSI platform – Petrofac E&C

Problems Solving Method

1. During the work of Provision of Computer Assisted Operations (CAO) at ANGSI-

B , as a trainee we have met several problems such as during entertaining the
client we have difficulty in satisfying their high standard of task, but it can act as
an experience for us.For example our production stated that they will be no
marking using low stress stamp on the pipe spool but Client Representative from
Integrity Engineering Services , QA/QC Engineer MR.Fauzan insisted that it
should be stamp to mark the joint number and spool number so that the stamp can
be permanent on the pipe even after the paint.After lenghty negotiation it is
decided that it is needed to stamp because it wont effect the chemical composition
of the material even with stamp but only if it is stamped on Flanges. The problem
is solved through negotiations.

2. During the work of Provision of gas jet pump application for ANGSI platform,
when the project already delivered , the client found that there’s is a defect on the
weldment (a clear visual defect) . They are furious on how it is pass for
Hydrostatic test n clear of all NDE. But the Pipe is already at the OFFSHORE
platform of ANGSI. So the client company want us to send all the Radiographic
Test Report and all other NDE report via email to them. The problem is later
solved by sending welder to repair at the site (ANGSI) .

26
 CHAPTER IV

CONCLUSION & RECOMMENDATION

 CHAPTER IV

CONCLUSION & RECOMMENDATIONS

During this Industrial training as a trainee I have learn so many valuable knowledge that

can be my advantages in the future and become more confident and equipped with

knowledge that are useful in the Oil and Gas industry. As a trainee and student of Unikl

Malaysia France Institute I am also very proud because most of the person I met in the

industry knows well of MFI and there are also some already successful Welding Engineer

and Inspectors started from MFI. As a trainee I learn all about being QC inspector during

my stint in Peer Mark Engineering. They have taught me how to handle a document ,

making visual inspection , read ISO drawing , P&ID , making NDE request, interacting

with client , about the material , about procedure , hydrostatic test, make my own format

of Radiographic Test percentage (failure) per Welder and how important is Radiographic

Test in the world of welding. Being involved in work environment in company, the

trainee had gained experience and a lot of things especially knowledge in manufacturing

and preparing documents. Preparing documents is not an easy work. Good

communication skill is needed in order to have proper documentation. This skill is

important to be applied not only communication between higher level of management,

but also with other staffs and human operators. Trainee also learned the culture of work

needed to be followed which is lean. Lean is a culture for continuous improvement

27
through waste identification, elimination, prevention and people will make this happen.

By applying and adapting

this culture, all jobs can be done systematically . In Peer Mark Engineering , trainee not

only learn about QC , but also Production where they need to interact with all the workers

in workshop and not only inspect the material but also get into production work as well.

Trainee also is involved as SAFETY officer as they also follow SAFETY officer

investigate if there’s is an accident in the workshop. Furthermore , a trainee in Peer Mark

Engineering gets no special attention as they are also treated the same like any other

employers and can also voice their idea’s. Peer Mark Engineering is an industry leader –

a company that thrives on providing the highest quality products and services to its

customers. The work environment is exciting and fast-paced. Peer Mark have built a

culture that encourages active participation and contribution by all. And it is all about

Team Work.

28
 Bibliography
1. Copy right reserved – PME 2006 , About us, http://peer-

mark.com/default.aspx

2. Copy right reserved – Metal One Engineering Sdn. Bhd. , About Metal

One , http://www.metalone-eng.com/

29
APPENDICES

33
Appendix 1 : Peer Mark Engineering Organization Chart

30
Appendix 2 : Radiographic Test report

31
Appendix 3 : Radiographic Test report

32
Appendix 4 : Hydrostatic Test report

33
Appendix 5 : Hydrostatic Inspection Report

34
Appendix 6 : Hydrostatic Test Pressure Sketch

35
Appendix 7 : Example of 1 of the Calibration Certificates

36
Appendix 8 : Welding Inspection Report

37
Appendix 9 : 1 of the Project ISO drawing Provision of Computer Assisted

Operation (CAO) at ANGSI-B

Appendix 10 : Example of Radiographic Test Request

38
PEER MARK ENGINEERING SDN BHD
Lot 8965 , Jalan Udang Galah, Telok Gong,
42000 Port Klng, Selangor Darul Ehsan. Malaysia Radiographic
Tel: 603-3134 3881 / 603-31343882 Fax : 603-3134 1398 P Test
Magnetic
NDT WORK ORDER JOB NO. : Particle Test
PME/1339/12 Ultrasonic Test
To : PRESCAN SDN. BHD From : Dye-Penetrant
FALIQ Test
Attn : Mr. Vincent / Mr. Jimmy Date : Hardness Test
15/3/12
Please carried out the following testing on: 15/3/12-10.00 p.m

Job / Item Acceptance Thk. Weld Process

No. Material SIZE Welder
No. Code (mm) Reference (FS)
ASME A105N~A1 8.74m
1. B04-06247-SP 1 2" Sch 160 J1 GTAW W057
B31.3 06 GR. B m

ASME A106 GR.

2. B04-06247-SP 1 2" Sch 160 8.74m J2 GTAW W057
B31.3 B ~ A105N
m

ASME A105N~A1
3. B05-06100-SP2 2" Sch 160 8.74m J1 GTAW W057
B31.3 06 GR. B
m

ASME A106 GR.

4. B05-06100-SP2 2" Sch 160 8.74m J2 GTAW W057
B31.3 B ~ A105N
m

ASME A105N~A1
5. B14-06232-SP5 2" Sch 160 8.74m J1 GTAW W057
B31.3 06 GR. B
m

ASME A106 GR.

6. B14Q-06232-SP5 2" Sch 160 8.74m J2 GTAW W057
B31.3 B ~ A105N
m
PROJECT: PROVISION OF COMPUTER ASSISTED OPERATIONS (CAO) AT
ANGSI-B

39
Appendix 11 : Blasting & Painting report and Inspection And Test Plan of Provision

of Computer Assisted Computer (CAO) at ANGSI-B

40
Appendix 12 : Company Certificates

41
Appendix 13 : Company Experience List

42
Illustration
Illustration 1 : Gas Skid of KBB Nothern Hub Project
43
Illustration 2 : Installation of GLNG skid

44
Illustration 3 : Visual Inspection on a Vessel by QC inspector before Hydrostatic

Test
45
Illustration 4 : Preheat before welding for KBB Northern Hub Project
46
Illustration 5 : Inspection of SILO for a Japanese company

47
Illustration 6 : Inspection and finding heat number for every material for Material

and fit-up inspection report for HIJAU GAS OIL Project (Air Tank).

48
Illustration 7 : Hydrostatic test is being carried out for GLNG project

49
Illustration 8 : The delivery of Provision of Computer Assisted Operation at ANGSI-

B to Terengganu

50
Illustration 9 : Removal of surface defect on a stainless steel dish head of its nozzle

weld

51
Illustration 10 : Unpacking the Ball valve for KBB Northern Hub Project

52