Beruflich Dokumente
Kultur Dokumente
DEDICATION
This report was dedicated to my parents who have supported me all the way since
the beginning of my studies till now.
Also, this report was dedicated to my siblings and not forgotten also my friends who
has been my great source of motivation and inspiration. Finally this report was
dedicated for all those who believe in the richness of learning.
STUDENT ADMISSION
I recognize this work is my own work except for excerpts and summaries of each of
them I have already explained the source.
Signature :
Name : MUHAMMAD HIDAYATURRAHMAN B RAHMAT
Registration No. : 01DKM12 F2043
Course : DIPLOMA OF MECHANICAL ENGINEERING
APPRECIATION
Praise to Allah for his blessings, I have finished this report as it is a
requirement for me to get the Diploma of Mechanical Engineering. A handful of
thanks I bid to Mr Wan Abd Rahman, my task evaluator and the staff of Petronas
Penapisan Melaka Sdn Bhd who helped me a lot by giving me useful information
and for pointing out my mistake so that my work will give out an excellent result.
Special thanks I bid to Mej. (K) Dato Hj Md. Nor Bin Yusof, the director of
Polytechnic Ungku Omar, for without him allowing the industrial training to be held,
there will be no field of experience for us. Also for academic advisor, coordinator of
the industrial training and lecturers who made this all possible for us by teaching
from the basic of mechanical engineering to the advance knowledge of the subject. I
am thankful for that because without any knowledge given to us earlier, we will not
be able to do anything due to lack of information about how engineering works.
I am nothing without my parents. Therefore, I would like to thank them for
giving me support that I needed to finish this course especially when it comes to
moral and financial support. Many thanks I bid also to my fellow friends for giving
me the spirit and showing me some things that I do not know during the period of
industrial training.
As a conclusion, this report will not finish successfully if I had not receive
help from other person above. I will be forever in debt for their good deeds that they
have done for me.
ABSTRACT
Industrial training is one of the necessary thing that need to be carried out by
the students in polytechnic. The polytechnic has fixed a period of one semester for
each student that have passed the prequisitory condition. Industrial training time span
starts from 23th June 2014 till 7th November 2014. This industrial training were
carried out to expose students to the real working experience on their respective
fields. Apart from that, this training aim for students to practice about what they have
learned during their earlier semester in polytechnic and they will improve their skill
in the field that they are involved in. The log book on the other hand is an overall
record during the industrial training. The log book contain industrial training
information of the organization, technical report, to record works carried out during
their training period and their summary, also contain comments and suggestion for
organization for future improvement. Overall, this log book will be presented to the
polytechnic to be evaluated and it will be used by polytechnic to understand more
about the work done by the students during the period of the training.
ABSTRAK
Latihan industri merupakan salah satu perkara wajib yang perlu dilaksanakan
oleh penuntut di politeknik. Pihak politeknik telah menetapkan jangka masa selama
satu semester bagi setiap pelajar yang melepasi syarat-syarat tertentu. Tempoh
latihan industri bermula dari 23 Jun 2014 hingga 7 November 2014. Latihan industri
ini diwujudkan bagi mendedahkan para pelajar terhadap bidang masing-masing
dalam dunia pekerjaan sebenar. Selain itu, latihan ini bertujuan untuk para pelajar
mempraktikkan apa yang dipelajari di politeknik sekaligus dapat meningkatkan ilmu
kemahiran dalam bidang yang diceburi. Buku laporan pula merupakan satu catatan
keseluruhan sepanjang pelajar menjalankan latihan industri . buku laporan ini
mengandungi maklumat latihan industri bermula dari maklumat organisasi, laporan
teknikal, catatan kerja-kerja yang dilakukan sepanjang tempoh yang diberi serta
rumusan, komen dan cadangan untuk organisasi bagi proses penambahbaikan pada
masa akan datang. Secara keseluruhannnya, buku laporan ini dipersembahkan untuk
pihak politeknik menilai dan memahami setiap kerja yang telah dilakukan oleh
pelajar semasa menjalani latihan.
Table of Content
Content
Page
Front Page
Dedication
Student Admission
Appreciation
Abstract
Table of content
Chapter 1 : Introduction
1.1 Preliminary
11
12
14
15
16
17
19
20
21
22
23
23
24
28
36
37
40
15
47
48
49
49
50
51
52
53
P O L I T E K N I K U N G K U O M A R | 10
53
57
Chapter 6 : Conclusion
59
Bibliography/ Reference
60
Appendix
62
P O L I T E K N I K U N G K U O M A R | 11
CHAPTER 1
INTRODUCTION
1.1
Preliminary
The industrial training was carried out at a firm or an organization whether
the student chooses it or it is given to them for one whole semester. The main
purpose of the industrial training is to produce graduates who ready and capable to
face their profession academically or non-academically with high professionalism
appearance.
P O L I T E K N I K U N G K U O M A R | 12
Other than that, the industrial training exposes the students about the real
situation of the working class citizen. The industrial training also helps in developing
social skills of the students.
1.2
1.2.1
i.
1.2.2
i.
P O L I T E K N I K U N G K U O M A R | 13
1.2.3
i.
1.2.4
i.
1.2.5
i.
P O L I T E K N I K U N G K U O M A R | 14
1.2.6
i.
1.3
Report Objectives
1.3.1
i.
ii.
iii.
iv.
v.
P O L I T E K N I K U N G K U O M A R | 15
1.4
1.4.1
i.
ii.
iii.
iv.
P O L I T E K N I K U N G K U O M A R | 16
CHAPTER 2
COMPANY BACKGROUND
2.1
History of PETRONAS
The growing demands of energy inspires and strengthens our purpose to deliver the
most essential and reliable sources of energy and the company aim to sustain that for
decades to come.
They apply innovative approaches to technology which helps them unlock and
maximize energy sources from even the most remote and difficult environments.
Their fully integrated pipeline and value chain spans from exploration to marketing,
logistics to technological infrastructures, with operations in over 50 countries around
the world. Throughout their rapidly expanding network, they constantly find new
P O L I T E K N I K U N G K U O M A R | 17
2.2
Petronas Penapisan (Melaka) Sdn. Bhd. [PP (M) SB], located in Sungai Udang,
Melaka, is a wholly-owned subsidiary of Petroliam Nasional Berhad or PETRONAS,
the
national oil corporation. PP (M) SB manages and operates the refinery complex in
Malacca. PP (M) SB is the second refinery complex in the country after the first
refinery
which was constructed in Kerteh, Terengganu. Petronas also has a third refinery in
Engen, South Africa. PP (M) SB consists of Petronas Second Refinery Phase 1 (PSR
1)
and Petronas Second Refinery Phase 2 (PSR 2). The Malacca refinery complex is
now
within an area of 926acres and is still expanding.
PSR 1, wholly owned by Petronas, was built-in in September 1987. Plant
operations were commissioned in 1994 processing local sweet feedstock
(sulfur<0.5wt
%) for the design capacity of 100,000 barrels per day (BPSD) utilizing
hydroskimming
configuration (sweet train).The main process units at PSR1 include:
1)
2)
3)
4)
5)
6)
7)
P O L I T E K N I K U N G K U O M A R | 18
P O L I T E K N I K U N G K U O M A R | 19
2.3
Boards of Director
1) Tan Sri Mohd Sidek Hassan (Chairman of the Board)
2) Tan Sri Dato Shamsul Azhar Abbas (President and Group Chief
Executive Officer)
3) Tan Sri Dr Mohd Irwan Serigar Abdullah
4) Tan Sri Amirsham A.Aziz
5) Datuk Muhammad Ibrahim
6) Dato Mohamad Idris Mansor
7) Tan Sri Dato Seri Hj Megat Najmuddin Datuk Seri Dr Hj Megat Khas
8) Krishnan CK Menon
9) Datin Yap Siew Bee
10) Datuk Mohd Omar Mustapha
11) Datuk Wan Zulkiflee Wan Ariffin
12) Dato Wee Yiaw Hin
13) Abdul Rahman Musa (Secretary)
P O L I T E K N I K U N G K U O M A R | 20
2.4
Managing Director/CEO
Other Departme
Plant Division
Other Departments
Technical Services Department
Health, Safety, Environment and Security Departmen
Technology Department
Production Department
Laboratory Department
Engineering Department
P O L I T E K N I K U N G K U O M A R | 21
P O L I T E K N I K U N G K U O M A R | 22
Department
Production
Function
All process operations including ultilities, storage and
shipping of feed and products are taken care by this
Engineering
department
Plant asset management, major maintenance,
maintenance engineering, reliabilitymanagement and
Refinery Planning
Table 1
2.7
P O L I T E K N I K U N G K U O M A R | 23
2.8
Shared Values
Our values are embedded in our culture as the backbone of our business conduct,
reflecting our sense of duty and responsibility in upholding our commitment towards
contributing to the well-being of peoples and nations wherever we operate.
2.8.1 Loyalty
Loyalty to nation and corporation
2.8.2 Integrity
Honest and upright
2.8.3 Profesionalism
P O L I T E K N I K U N G K U O M A R | 24
PP(M)SB Facilities
2.9.1 Storage Tank
Fig. 2.1
2.9.2 Jetty
P O L I T E K N I K U N G K U O M A R | 25
Fig 2.3
2.9.4 Multi Product Pipeline
Fig 2.4
P O L I T E K N I K U N G K U O M A R | 26
Fig. 2.5
Fig. 2.6
P O L I T E K N I K U N G K U O M A R | 27
Fig 2.7
2.9.8 Laboratory
Fig 2.8
P O L I T E K N I K U N G K U O M A R | 28
CHAPTER 3
WEEKLY SUMMARY
3.1
Introduction
In undergoing industrial training, students are disclosed with a whole lot of new
things. Apart from practicing what we had learnt in polytechnic, students also gain
the opportunities to experience real work according to their courses themselves by
doing assignment that have been provided by their supervisor. By doing so, students
are able to increase their self-confidence upon entering the real working world on
future. On the other hand, students had to obey every rule provided by the firm and
polytechnic at the same time which will improve their discipline.
3.2
Following is the summary of all the activity carried out during training period
weekly.
Week 1
P O L I T E K N I K U N G K U O M A R | 29
Week 2
Week 3
Week 4
P O L I T E K N I K U N G K U O M A R | 30
2)
3)
4)
5)
6)
Week 5
Week 6
(28th July- 1st August 2014)
1) Replace rubber coupling
2) Perform alignment on mixer motor
3) Preventive maintenance job on vessel
Week 7
P O L I T E K N I K U N G K U O M A R | 31
Week 8
Week 9
Week 10
Week 11
P O L I T E K N I K U N G K U O M A R | 32
Week 12
Week 13
Week 14
P O L I T E K N I K U N G K U O M A R | 33
Week 15
(29th September- 3rd October 2014)
1)
2)
3)
4)
5)
6)
7)
Week 16
Week 17
Week 18
P O L I T E K N I K U N G K U O M A R | 34
Week 19
Week 20
P O L I T E K N I K U N G K U O M A R | 35
CHAPTER 4
TECHNICAL REPORT
P O L I T E K N I K U N G K U O M A R | 36
P O L I T E K N I K U N G K U O M A R | 37
Multi-stage pumps
Pumps with more than 1 impeller are called multi-stage pumps. Each impeller is
referred to as a stage. A pump with 5 impeller is a 5 stage pump.
There are 3 common types of multi-stage pumps:
Fig 4.1.2.1
1) Submersible
P O L I T E K N I K U N G K U O M A R | 38
the surface to the motor. These pumps are used for lifting water or oil from
any depth. The pump capacity is limited by the size of the casing. An electric
power source is required at the surface to operate the pumps.
Fig. 4.1.2.2
2) Can-type vertical
Can-type vertical pumps are used to lift liquids from sub-surface sources such
as sumps and caissons. The pump driver is located at or above the liquid
surface, and the shaft extends from the driver to the pump, which may be
located some distance below the liquid surface. Multi-stage can-type pumps
are frequently installed on offshore platforms to provide and emergency
firewater supply.
Fig 4.1.2.3
3) Horizontal multi-stage
P O L I T E K N I K U N G K U O M A R | 39
Horizontal multi-stage pumps are used in process plants and oil pipelines
where the pump must increase the liquid pressure several hundred psig. There
is no theoretical limit to the number of impellers in a horizontal pump, but
more than 8 are seldom used.
1) Reciprocating
2)
Reciprocating pumps are classified by the features:
i) Drive end (power or direct-acting)
ii) Orientation or centerline of the pumping element (horizontal or
vertical)
iii) Number of discharge stroke per cycle of each drive rod (single-acting
or double-acting)
iv) Configuration of the pumping element (piston, plunger, or diaphragm
pump)
v) Number of drive rod (simplex, duplex, multiplex)
The number of combination is almost endless. The power provided by a motor or
engine in a rotary can be changed into reciprocating motion in the same mechanical
manner that an automobile engine changes reciprocating power strokes into a rotary
movement of the crankshaft. This action is reversed in a power driven reciprocating
pump.
P O L I T E K N I K U N G K U O M A R | 40
Fig 4.1.2.2.1
i)
Fig. 4.1.2.2.2
ii)
Plunger pumps
To obtain higher pressure than piston pump, another type of pump end-a
plunger is used
P O L I T E K N I K U N G K U O M A R | 41
Fig. 4.1.2.2.3
iii)
Diaphragm pump
Compressed-air operated diaphragm pumps are widely used in oil and gas
process plants for handling slurries, mud etc. a diaphragm of flexible nonmetallic material can better withstand corrosive or erosive action than
metal parts of some reciprocating pumps.
3) Rotary
Rotary pumps consist of a fixed casing containing gears, vanes, pistons,
cams, segments, screws operating with minimum clearances. Instead of
throwing the liquid as in a centrifugal, a rotary pump traps it, pushing it
around the closed casing, much like a piston of a reciprocating pump. But
unlike a piston pump, a rotary pump discharges a smooth flow.
Example of rotary pump:
P O L I T E K N I K U N G K U O M A R | 42
Fig 4.1.2.2.4
i)
Fig 4.1.2.2.5
ii)
P O L I T E K N I K U N G K U O M A R | 43
Fig 4.1.2.2.6
iii)
Lobular pump
These resemble the gear-type pumps in a action and have 2 or
more rotors cut with 2, 3, 4, or more lobes on each rotor. The
rotors are synchronized for positive rotation by external gears.
Because liquid is delivered in a smaller volumes but at greater
frequency than in the gear pump, flow from lobular type pump is
not quite so constant as from the gear type.
P O L I T E K N I K U N G K U O M A R | 44
Fig 4.1.2.2.7
iv)
Screw pumps
These have one, two, or three suitably threaded screws turning in a
fixed casing. A large number of designs are available for various
applications.
Single-screw pumps have a spiraled rotor turning eccentrically in
an internal-helix stator or liner. The rotor is metal while the helix
is hard or soft rubber, depending on the liquid handled.
Two and three-screw pumps have one or two idlers, respectively.
Flow is between the screw threads, along the axis of the screws.
Opposed screws may be used to eliminate end thrust in the pump.
P O L I T E K N I K U N G K U O M A R | 45
Fig 4.1.2.2.8
v)
Vane pumps
Sliding-vane pumps use vanes that are held against the casing bore
by centrifugal force when the rotor is turned. Liquid trapped
between two vanes is carried around and forced out the pump
discharge.
P O L I T E K N I K U N G K U O M A R | 46
Before actually starting up the equipment, the following is a checklist of items that is
recommended to be looked at.
1. For pumps with double mechanical seals or packing with external gland oil,
the gland oil supply piping should be cleaned by oil or solvent flushing prior
to connecting to the pump.
2. For pumps with tandem mechanical seals, the overhead reservoir and all flush
oil supply piping should be thoroughly cleaned by oil flush prior to
connecting to the pump.
3. It is important for good seal or packing performance that dirt or foreign debris
not be introduced into the seal or packing cavity.
4. The flushing and steaming of pumps with single or tandem mechanical seals
should be held to a minimum period of time. This will minimize the amount
of debris entering the seal cavity, and prevent the destruction of the static seal
5.
element by overheating.
All cooling water piping on pumps and turbines should be flushed and
P O L I T E K N I K U N G K U O M A R | 47
P O L I T E K N I K U N G K U O M A R | 48
5. The mechanical seals should be checked for leakage particularly during the
first hours of operation. A minor leak through the seal usually stops after a
short time, but if it continues, the pump should be stopped and the seal fixed.
6. When operating the pump at a discharge below the rated point, the motor
should be watched carefully. The discharge valve should be throttled to build
up head to a safe point. Should the low heat condition persist, the pump
should be shut down. Centrifugal pumps should not be operated at greatly
reduced capacity or with the discharge valve pinched because the energy
required to drive the pump converted into heat and the temperature of the
liquid may reach the boiling point. Furthermore, many pumps are subject to
flow instability at low flows.
temperature.
5. Close all the valve that supply cooling water to the bearings, housings or
water cooled stuff boxes.
6. If the sealing liquid supply is not required while the pump is idle, close the
valve in this supply line.
7. Close the suction valve, open the drain valves, as required by the particular
installation or if the pumps is to be opened up for inspection.
4.1.4
Pump maintenance
P O L I T E K N I K U N G K U O M A R | 49
Intervals
Daily
i.
ii.
iii.
iv.
v.
Routine
Check pump for noisy bearings and cavitation noise
Check bearing oil for water, discoloration and contamination
Feel all bearings for temperature. Check oil level
Check packing glands for excessive leakage
Inspect bearings and oil rings through filling ports. Wipe
vi.
P O L I T E K N I K U N G K U O M A R | 50
vii.
Monthly
Yearly
viii.
i.
ii.
iii.
good condition.
Determine if mechanical seal condition is normal
Add oil if required
Check packing gland for shaft wear
Ascertain that oil level is correct distance from shaft center
iv.
v.
vi.
i.
ii.
iii.
iv.
open
Replace guards (repair if required)
Determine if pump unit requires general cleaning by others
Check impeller wear and wear rings
Check bearing wear
Do seasonal oil change-out if required by Lube Guide
Dial indicators check coupling alignment in coupled condition.
Use special coupling indicator clamps where possible. Ensure
v.
vi.
vii.
similar manner
Replace gasket. Clean and paint pump housing
4.1.5
P O L I T E K N I K U N G K U O M A R | 51
ii.
lubricating oil.
Check valves in the suction line and discharge line from the pump to
see that liquid can enter the pump and discharged liquid is routed to
iii.
Caution:
Before starting a positive displacement pump, valves in the suction and
discharge line on the liquid end should always be open. If the pump is started
with a closed discharged valve, pressure in the discharge line may rise high
enough to burst the line.
Positive displacement pumps are controlled so that they pump the volume of
liquid available to them. In some operating situations, the pumps operate at a
constant flow rate, and no control is provided. An example of this type of
operation are glycol pumps, these pumps usually have a motor drive and they
operate at a constant speed.
There may be occasions when flow from a constant speed pump needs to be
reduced. The only practical method common to all positive displacement type
P O L I T E K N I K U N G K U O M A R | 52
pumps is to open valve in a bypass line so that some of the discharge liquid
flows back into the suction line.
PROBLEM
Low pump capacity
CAUSE
1. Driver low speed
2. Cavitation or vapour
lock. Pump vibrates
and discharge
pressure varies
3. Leaking suction/
CORRECTIVE ACTION
Check for loose, worn, or broken
belts and correct.
Increase liquid level in vessel
being pumped to increase Net
Positive Suction Head(NPSH).
discharge pump
valves or piston
rings. Pump is noisy
4. High head pressure.
P O L I T E K N I K U N G K U O M A R | 53
Suction pressure is
low. Pump stalls
5. Pump bypass valve
open or relief valve is
leaking
material is used
2. Lack of lubrication
3. Packing and rod are
hot
4. Worn rod
5. Liquid contain solid
particles
Frequent failure of
1. Pulsation. Pump
valves or piston
rings
particles
3. Vapour
lock
4. Anchor bolts are
Bearing or
crankshaft failure on
motor or engine
driven pump
vibrates
1. Lack of lubrication
2. Belts are too tight
3. Main bearings are too
tight or too loose
4. Misalignment
between pump
or remove shims to
manufacturers specifications
Align to manufacturers
specification
Table 4.1.5 .4.1 Troubleshooting reciprocating pumps
P O L I T E K N I K U N G K U O M A R | 54
8)
P O L I T E K N I K U N G K U O M A R | 55
CHAPTER 5
Apart from that, there are also a few matters that need to be improved by either the
Polytechnic or the firm or the company itself. Among the improvement that I wish to
suggest are:
P O L I T E K N I K U N G K U O M A R | 56
P O L I T E K N I K U N G K U O M A R | 57
CHAPTER 6
CONCLUSION
P O L I T E K N I K U N G K U O M A R | 58
objective which to produce a workforce that are high in quality and partially
professional in this country.
P O L I T E K N I K U N G K U O M A R | 59
Bibliography/ References
1.
2.
3.
4.
Hj Jailani Ismail, Single Stage Centrifugal Pump, INSTEP, Batu Rakit, 2007
www.petronas.com.my/about-us/our-leaders/Pages/board -of-directors.aspx
http://en.m.wikipedia.org/wiki/Pump
Philip L. Skousen, Valve Handbook Third Edition, McGraw Hill, 2011
P O L I T E K N I K U N G K U O M A R | 60
APPENDIX