Engineering Internship

Pengenalan struktur Engineering, Maintenance, Utility, Production, EHS. Safety induction, aturan area kerj, LOTO awareness, permit to work. Mengenal proses produksi dan utility.

Pengenalan ISO 50001, energy policy, energy review, Significant Energy Use/SEU, energy performance, EnPI dan energy baseline.

Mempelajari sistem cooling existing. Mengumpulkan kapasitas, COP, power input, cooling tower water supply/return temperature, flow rate dan operating hours.

Membandingkan kebutuhan panas absorption chiller dengan waste heat chimney. Menentukan apakah temperatur dan heat flow cukup.

Mengidentifikasi kebutuhan listrik auxiliary equipment, instrumentation, control panel, interlock dan monitoring system.

Menghitung saving rupiah/tahun, CAPEX, OPEX, payback period, ROI dan sensitivity analysis.

Identifikasi equipment utama: boiler/furnace, chimney, compressor, pump, cooling tower, chiller, electrical system, utility equipment. Memahami fungsi dan hubungan antar equipment.

Membuat energy flow diagram dari incoming energy sampai end-use. Identifikasi sumber energi listrik, gas, steam, thermal energy dan cooling system.

Survey chimney sebagai potential waste heat source. Mengukur/mengumpulkan temperatur exhaust, flow, pressure, operating hours dan karakteristik gas buang.

Membuat konsep sistem: chimney → heat recovery → absorption chiller → chilled water system. Menentukan equipment utama dan instrumentasi.

HAZID/JSA sederhana. Analisis risiko hot gas, high temperature, pressure, chemical, steam/hot water, rotating equipment dan maintenance access.

Membuat implementation schedule, procurement requirement, installation sequence, shutdown requirement, commissioning plan dan responsibility matrix.

Belajar preventive, predictive dan corrective maintenance. Review PM checklist, breakdown history, spare parts dan maintenance schedule.

Mengumpulkan data konsumsi listrik, fuel/gas, operating hours, production output, chiller load, cooling water temperature, ambient condition dan data utility.

Menghitung estimasi energi panas yang tersedia dari chimney. Analisis heat recovery potential berdasarkan data aktual.

Membuat preliminary PFD/P&ID. Menentukan piping, valve, pump, heat exchanger, sensor temperature, pressure, flow dan control point.

Mengestimasi CAPEX: absorption chiller, heat exchanger, pump, piping, valve, instrumentation, electrical, installation dan commissioning.

Finalisasi studi kelayakan pemasangan absorption chiller dengan memanfaatkan waste heat dari chimney. Melakukan review seluruh data teknis, heat balance, cooling demand, energy saving potential, CAPEX, OPEX, payback period, risiko teknis, kebutuhan maintenance, serta aspek operasional. Membuat perbandingan existing condition vs proposed system dan menyusun rekomendasi apakah project layak dilanjutkan ke tahap engineering/implementasi.

Survey kondisi aktual equipment yang berkaitan dengan energy consumption. Inspeksi visual, temperatur, pressure, vibration, leakage, abnormal noise dan operating condition.

Menentukan baseline energi. Mengembangkan EnPI yang relevan dalam kWh/ton produk.

Mempelajari prinsip kerja absorption chiller, tipe LiBr-water atau teknologi yang sesuai, heat source requirement, COP, cooling capacity dan auxiliary power.

Melakukan preliminary sizing heat exchanger, pump, piping dan absorption chiller berdasarkan heat balance dan cooling demand.

Membandingkan kondisi existing vs proposed. Hitung pengurangan electrical consumption, thermal energy utilization, cooling cost dan potential energy saving.

Menyusun laporan akhir seluruh kegiatan 24 minggu. Merangkum kondisi existing, energy review, EnPI, energy baseline, waste heat potential, konsep absorption chiller, preliminary design, energy saving calculation, financial analysis, risk assessment dan hasil feasibility study. Menyiapkan slide presentasi dan menyampaikan hasil project kepada Engineering/Management.