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INDUSTRIAL TRAINING REPORT 2015

NAME

MUHAMMAD ARIFF FATHI BIN MAWARDI( 2012632884)

PROGRAM

BACHELOR OF ENGINEERING (HONs) CHEMICAL AND PROCESS

COURSE

CHE690

CLASS

EH2217A

COMPANY

LINDE GROUP

DEPARTMENT

SAFETY HEALTH ENVIRONMENT AND QUALITY(SHEQ)

INDUSTRIAL

MS PANIMALAR BASKARAN

SUPERVISOR

LINDE MALAYSIA

Contents
ACKNOWLEDGEMENT..................................................................................................................3
ABSTRACT...................................................................................................................................... 4
DISCLOSURE STATEMENT...........................................................................................................5
INTRODUCTION............................................................................................................................ 6
CONTENT........................................................................................................................................ 7
Company Background..................................................................................................................7
Golden Rule............................................................................................................................10
Air Separation Units(ASU).........................................................................................................11
INTRODUCTION....................................................................................................................11
PLANT DESIGN AND PROCESS FLOW................................................................................11
SAFETY AND ENVIRONMENTAL IMPACT..........................................................................11
LOCATION OF AIR SEPARATION UNIT..............................................................................11
RAW MATERIAL....................................................................................................................13
PROCESS DIAGRAM.............................................................................................................15
MINI PROJECT............................................................................................................................. 16
Safety data sheet class 2013.......................................................................................................16
SHEQ booth exhibition..............................................................................................................17
WEEKLY INTERNSHIP ACTIVITY...............................................................................................19
WEEK 1....................................................................................................................................... 19
WEEK 2...................................................................................................................................... 20
WEEK 3...................................................................................................................................... 21
WEEK 4...................................................................................................................................... 22
WEEK 5...................................................................................................................................... 22
WEEK 6...................................................................................................................................... 23

MUHAMMAD ARIFF FATHI BIN MAWARDI


Degree of Chemical and Process Engineering(HOns)

LINDE MALAYSIA

ACKNOWLEDGEMENT
In the name of Allah the most gracious and merciful. Infinite praise to Allah the creator
for His thousand bless for me to finally complete this industrial training report. Massive thanks
to Mr Chan Choon Bim, the head of SHEQ department for giving me this opportunity to do an
internship program with Linde Malaysia. In my opinion it was an invaluable experience to be a
part of SHEQ team and learn how the team ensure the safety management aspect but at the
same time, achieving the company sales target. In addition, I can apply all my knowledge and
study in safety courses to help providing useful idea in order to improve the safety aspect at the
company.
Endless thanks and appreciation to my industrial supervisor or to be honest, my mentor
during the training period, Ms Panimalar Baskaran for all her time and dedication prior to my
training. Under her help and guidance, I manage to complete my industrial training with
challenging working experience in real industry environment as a chemical engineer specifically
in safety perspective.
Moreover, a special thank to our beloved coordinator, Madam Asdarina for her
hardworking and advice to us in order to secure our training placement before and after the
training. Last but not least, to my lovely parent, siblings, friends and not to forget all the Linde
Malaysia staff for their support and encouragement. Without them I would not be able to finish
my training successfully.

MUHAMMAD ARIFF FATHI BIN MAWARDI


Degree of Chemical and Process Engineering(HOns)

LINDE MALAYSIA

ABSTRACT
This report is written to describe all the activity along my 10 weeks of industrial
training. The activity involving my completion of mini projects assigned to me, training
involvement, plants site visit and daily activity during the period. The focus will be more on my
mini project which is Safety data sheet compliance and SHEQ booth exhibition. Objective and
benefit of all the activities will be detailed down and discussed further in order to have a better
understanding.

MUHAMMAD ARIFF FATHI BIN MAWARDI


Degree of Chemical and Process Engineering(HOns)

LINDE MALAYSIA

DISCLOSURE STATEMENT
This is to declare that I have read the report and that the information enclosed is correct and
contains no confidential information.

Company

: Linde Malaysia

Industrial Supervisors Name

: Panimalar Baskaran

Position

: SHE Engineer

Signature

Date

MUHAMMAD ARIFF FATHI BIN MAWARDI


Degree of Chemical and Process Engineering(HOns)

LINDE MALAYSIA

INTRODUCTION
Industrial Training is one of the requirements for the completion Degree of Chemical and
Bioprocess Engineering, under the Faculty of Chemical Engineering, Universiti Teknologi
MARA. These are the objectives of industrial training ;
-

To communicate effectively with fellow workers and supervisors on issue related to


project given
To demonstrate organizational skills and team work to carry out project given
To perform basic engineering practices or research activities, including technical
writing and project management
To demonstrate the creativity and innovation in solving problems related to real life
project
To demonstrate high level of integrity, ethical and accountability in engineering
practices

The training was completed in 10 week time, beginning from 13 th July 2015 until 18th September
2015. I was accepted to done my training at Linde Malaysia and was attached to Safety Health
Environment and Quality (SHEQ) Department, and reporting to Ms Panimalar Baskaran, a SHE
engineer and officially my industrial supervisor.

MUHAMMAD ARIFF FATHI BIN MAWARDI


Degree of Chemical and Process Engineering(HOns)

LINDE MALAYSIA

CONTENT
Company Background

The company begins the business in 1960 named Malayan Oxygen Limited. During that
time, this new company supply gases to various industries in petrochemical, electronics, steel
and high technology companies. In 1974, the company grows their business in welding by
supplying the electrode for the welding parts. 5 years later Malayan Oxygen Limited merged
with Far East Oxygen to form Malaysian Oxygen Berhad which then being a public listed
company on the main board of Kuala Lumpur Stock Exchange (KLSE). In 1998, the company
improves their business by established the customer service centre. 2 years later, Malaysian
Oxygen Berhad acquired Nissan Industrial Oxygen, one of the company competitors during that
time thus widen their influenced in the gas industry. Later on in 2007 The Linde Group bought
ALs shares in ALBOC Jersey and wholly owned on subsidiary of the company and changed the
name to MOX-Linde. After celebrating the 50th anniversary year in Malaysia in 2010, the
company then officially renamed to Linde Malaysia.

MUHAMMAD ARIFF FATHI BIN MAWARDI


Degree of Chemical and Process Engineering(HOns)

LINDE MALAYSIA
Linde Malaysia has been the industrial gases market leader in Malaysia for the past 50 years.
Throughout this period, Linde Malaysia has expanded its footprint throughout the nation with
well established infrastructure to support diverse industries through supply and service
reliability. With the most comprehensive gases product portfolio and direct sales network in the
country, more than 20 sales centres and 60 plants nationwide, this company specialize in
providing total gas solutions to a variety of industries. They manufacture and distribute
industrial, specialty and medical gases, and provide a range of related services including the
installation of gas equipment, pipelines and associated engineering services. In addition, they
also supply packaged chemicals, and welding and consumables products. Organization

Chart SHEQ Department

The portfolio of each position is slightly difference from one another but the SHEQ team
actually is emphasizing the core of the company safety which is the golden rules. The Golden
Rules are among the pillar of the company that are based on incidents and experiences in the
company and also reflect legal and regulatory requirements that apply in many of the countries
in which Linde operates. The Golden Rules reinforce those critical areas of our existing
management system that present a high risk of serious injury or fatality if not followed.
Therefore, they must be adhered to at all times by everyone. In addition, local regulations and
other Linde specific requirements must also be applied. In general anything related to the safety
and quality of the company, customer and environment will be SHEQ department concern.

MUHAMMAD ARIFF FATHI BIN MAWARDI


Degree of Chemical and Process Engineering(HOns)

LINDE MALAYSIA

Golden Rule
Consist of 8 major parts:
1. Personal ownership for safety // We will consistently demonstrate
personal ownership and accountability for safety through our actions
and behaviours.
2. Driving and vehicles // We will operate our vehicles safely and
responsibly at all times and use the safety equipment provided.
3. Permit to work // We will use the permit to work system where
necessary to ensure hazards and risks are understood and controlled.
4. Working at height // We will only work at height when the required
safety measures to prevent falls are in place.
5. Lifting operations // We will ensure lifting operations utilising cranes
or other lifting devices are carried out safely.
6. Contractor management // We will select and manage our contractors
so that they meet The Linde Groups safety requirements.
7. Engineering management of change // We will only proceed with
technical changes to process plants and process equipment when an
engineering management of change process addressing the safety risks
has been completed.
8. Incident reporting // We will report and investigate incidents so that
the causes can be identified and corrected, and learning shared.

MUHAMMAD ARIFF FATHI BIN MAWARDI


Degree of Chemical and Process Engineering(HOns)

LINDE MALAYSIA

Air Separation Units(ASU)


INTRODUCTION
Air separation can be classified into 2 types;
i.

Cryogenic air separation unit


A cryogenic air separation unit (ASU) is a process plant in which air is separated into
component gases by distillation at low temperatures. The plant comprises an assembly of
distillation columns, heat exchangers, adsorbers, and supporting machinery for
compression, expansion and control of gases and liquids. The component gases are sold and
distributed to customers for a wide variety of industrial, medical and other specialist
applications.

ii.

Non-Cryogenic air separation unit


It is possible to separate air into oxygen or nitrogen without using low temperatures through
the use of Pressure Swing Adsorption. Non-Cryogenic Systems are mainly used for smallscale production, typically less than 100 tonnes per day.
PLANT DESIGN AND PROCESS FLOW
The design of an air separation plant depends on the scale of operations and the nature of the
products required from it. While basic principles are always the same, process cycles and flows
for each plant can vary significantly. Linde tonnage air separation plants operate on a range of
different process cycles. Plants are designed and engineered to meet specific customer
requirements, in a range of plant capacities extending to production of over 2,300 tonnes per
day of oxygen, with co-production of nitrogen and argon.

SAFETY AND ENVIRONMENTAL IMPACT


Oxygen is a hazardous material and mis-operation of an air separation plant can lead to large
energy releases with hazards to personnel and equipment. Operation must always be in
accordance with specified safe practice. The air separation process is intrinsically clean and does
not generate undesirable side products. However, because it is energy intensive, it indirectly
causes release of a significant quantity of greenhouse gases. Therefore it is important to operate
a plant in the most efficient manner, both to minimise cost and reduce the impact on the
environment. While the raw material is free, ASU plants are energy-intensive. For example, a
unit making 2,000 tonnes per day of oxygen consumes around 30 megawatts (MW) of
electricity. The plants main machinery (the air feed and product compressors) accounts for the
major part of power consumption.

LOCATION OF AIR SEPARATION UNIT


Industrial gases are only transported over distances that are economically viable. Since these
distances are limited by transport costs and the physical properties of the gases, production
MUHAMMAD ARIFF FATHI BIN MAWARDI
Degree of Chemical and Process Engineering(HOns)

LINDE MALAYSIA
facilities are located close to the markets they serve. For higher value products (eg, argon,
helium, speciality gases), it may be feasible to locate the plant some distance from the customer.
Typically, air separation sites are located close to large tonnage customers such as:
I.
II.
III.
IV.
V.

steelworks
chemical works
petrochemical plants
oil refineries, and
smelters

so that the gas may be supplied directly to the customer by pipeline.

MUHAMMAD ARIFF FATHI BIN MAWARDI


Degree of Chemical and Process Engineering(HOns)

LINDE MALAYSIA

RAW MATERIAL
i.
Feed air
The raw material for air separation is air from the atmosphere, called feed air on an air
separation site.
ii.

Main Component
Air from the atmosphere is made up of a mixture of several gases. The main components
are nitrogen, oxygen and argon, with other gases present in smaller quantities.
Water vapour is also present in feed air. The water content of air varies considerably with
local ambient conditions. This diagram shows the main components of dry air.

This table lists other typical components of feed air.


Component

Volume (% of air)

Water vapour

Varies with temperature, humidity and


pressure (see note 2 below)
0.035 (Concentration varies and can be
as high as 0.1% near chemical
plants or power stations.)

Carbon dioxide

Helium

0.005

Neon

0.0016

Krypton
Xenon

0.0011
0.000008

Carbon monoxide
Sulphur dioxide

Varies according to local conditions.


Varies according to local conditions.

Nitrogen dioxide
Hydrogen sulphide

Varies according to local conditions.


Varies according to local conditions.

Ammonia

Varies according to local conditions.

Methane

Varies according to local conditions.

MUHAMMAD ARIFF FATHI BIN MAWARDI


Degree of Chemical and Process Engineering(HOns)

LINDE MALAYSIA
Other hydrocarbons

MUHAMMAD ARIFF FATHI BIN MAWARDI


Degree of Chemical and Process Engineering(HOns)

Varies according to local conditions.

LINDE MALAYSIA

PROCESS DIAGRAM
The basic process for large scale air separation has remained unchanged for decades. In this
process:
i.
ii.
iii.

air is compressed, then purified by removing carbon dioxide and water vapour
cooled to nearly its liquefaction temperature, and then
separated by fractional distillation into oxygen, nitrogen and argon products.

This diagram provides a very simplified overview of the air separation process. Each air
separation plant has a different, much more complex version of this process. The function of
each piece of equipment is then described. The warm equipment includes all of the equipment
that operates at ambient temperature or above. The cold equipment is housed inside the cold
box.

MUHAMMAD ARIFF FATHI BIN MAWARDI


Degree of Chemical and Process Engineering(HOns)

LINDE MALAYSIA

MINI PROJECT
Safety data sheet class 2013
i.

Occupational Safety and Health (Classification, Packaging and Labelling of Hazardous


Chemicals) Regulations 1997 (CPL Regulations)
The above regulation is a mechanism to control the supply of hazardous chemicals to the
workplaces in Malaysia and came into force on 15th April 1997. The regulation is comply
to all the supplier which the "Supplier" is referring to a person who includes a
formulator, a manufacturer, an importer or a distributor. Hazardous chemical is any
chemical which possesses any of the following properties in Schedule I of the
regulations: explosive, oxidising, extremely flammable, highly flammable, flammable,
very toxic, toxic, corrosive, harmful, irritant, or if relevant information exists to indicate
that the chemical is hazardous.

ii.

The Occupational Safety and Health (Classification, Labelling and Safety Data Sheet of
Hazardous Chemicals) Regulations 2013 (CLASS Regulations)
The Occupational Safety and Health (Classification, Labelling and Safety Data Sheet of
Hazardous Chemicals) Regulations 2013 (known as CLASS Regulations) were gazetted
on 11 October 2013 and officially introduced GHS into Malaysia.
A manufacturer or importer is required to prepare an inventory of hazardous chemicals,
imported or supplied in a quantity of 1 ton per year or above for each calendar year. Such
an inventory shall be submitted to the Department of Occupational Safety and Health no
later than 31 March in the following year.
CLASS regulations also require chemical manufacturers, importers, formulators, and
distributors to classify, label and package chemicals, and compile safety data sheets
according to the Industry Code of Practice(ICOP) which is aligned with UN GHS Rev. 3.
ensure suppliers of hazardous chemicals provide sufficient information on hazards of
chemicals that they supply, so as to mitigate the risk of accidents happening in the
workplace, thus providing a safe and healthy working environment and conditions. This
new regulation then is replacing the previous 1997 regulations.

Therefore, my task is to convert all the chemical product gases produce by Linde from
old CPL regulations which is generated from Germany to this new CLASS regulations
comply in Malaysia. In general, the SDS is divided into 3 classifications; Pure gases,
Industrial Mixtures gases and Special gases. Approximately about 570 chemical gases
produced by Linde Malaysia.

MUHAMMAD ARIFF FATHI BIN MAWARDI


Degree of Chemical and Process Engineering(HOns)

LINDE MALAYSIA

SHEQ booth exhibition


SHEQ head of department Mr Chan Coon Bim has assigned me to manage a side event of
CICM(Chemical Industrial Council Malaysia) responsible care run which is open up
booth exhibition representing SHEQ department. This is due to high responsibility and
concern of current alarming rate of road accident in Malaysia. Therefore the HOD took
an initiatives to create safety awareness among the road user especially the motorcyclist
which is the major contribution of the fatality accident statistics in order to reduce the
figures. Thus my assignment is to prepare a booth exhibition regarding to road safety
and also come up with an interesting games that create safety awareness at the same
time. This task might differ and not really related to chemical engineering yet has several
advantages on me especially building my soft skills and leadership, social networking,
event management and critical thinking. In the nutshell, experienced me to become
more flexible and open minded to tackle a new challenge.
i.

Games:
Show me the way

Game Objectives:
a. To assure that the motorcyclist obey the safety rules on the road.
b. To ensure the motorcyclist to fully concentrate and stay focus during riding.
c. This game clearly shows that without one of our sense we tend to involve in accident

MUHAMMAD ARIFF FATHI BIN MAWARDI


Degree of Chemical and Process Engineering(HOns)

LINDE MALAYSIA
ii.

Minutes Safety

Game Objectives:
a) To nurture safety attitudes and behaviors on the road by creating safe environment
condition.
b) To create awareness on road safety during riding or driving.
c) To prove to motorcyclist those safety measures take less than one minute time.

MUHAMMAD ARIFF FATHI BIN MAWARDI


Degree of Chemical and Process Engineering(HOns)

LINDE MALAYSIA

WEEKLY INTERNSHIP ACTIVITY


WEEK 1
13th July-15th July 2015
On the first day, I have joined Contractor Safety Pass Training by SHE Engineer Mr Dinesh Raj.
The training is given to all contractors hired by Linde Malaysia which cover safety regulation
regarding contractors job. All the potential hazard and risk have been described briefly for their
guidelines. The training end with a test to qualified and ensure the contractors understanding.
Besides that, I have been introduced to one of the incident reporting management website
named Synergi. The Synergi can be used to lodge a report, analyse and review current and
previous case investigation. There was a weekly short session which take about 5-10 minutes
that must be joined by all the Linde Pinnacle staffs named Take 5. During the session, all the
staff selected staff will be presenting about anything regarding to safety such as safety driving,
safety walking, internet security and etc. Take 5 session discuss about what to do in case of
elevator trapped and fire at the office.
Reading of the week:
i.
ii.
iii.
iv.
v.

Emergency response for Linde Hicom Plant


The rules of work by Macleod
Safety Data Sheet(latest review)
CIMAH report for Hicom Plant(Rev02,Nov13)
CIMAH report for Perai Plant(2nd submission, Rev01,Aug13)

MUHAMMAD ARIFF FATHI BIN MAWARDI


Degree of Chemical and Process Engineering(HOns)

LINDE MALAYSIA

WEEK 2
21st July-24th July 2015
During the 2nd week I have been given a desktop computer for me to complete any task assigned
by industrial supervisor, head of department or other SHEQ staffs. I also got my 1 st mini
assignment which is Safety Data Sheet Class 2013. I have been assigned to convert the pure
gases about 50 gases in one week. The take 5 session this week discuss about personal injury and
what to do during natural disaster occurrence. In addition I have been provided with coverall
and safety equipment for preparation for plant site visit. On the 24 th of July, I have joined safety
meeting at Linde Hicom ASU-ROC plant. Besides attended the meeting, I have been given a tour
to the plant to overview the plant process specifically for air separation unit. I have also joined
the plan working safety inspection and risk hazard assessment at the plant. The plant is a
Remote Operating Center which referring to the plant capability to control other plants in other
13 countries online. The ROC are managed and controlled by process control engineers which
cover all the regional east asia.
Reading of the week:
i.
ii.
iii.
iv.

Process description for ASU


Guideline to Globally Harmonized System
ASU general
ASU hazards and loss prevention

MUHAMMAD ARIFF FATHI BIN MAWARDI


Degree of Chemical and Process Engineering(HOns)

LINDE MALAYSIA

WEEK 3
27th July-2nd August 2015
SHEQ department has a short Monday morning meeting named Huddle Meeting which in the
meeting all the SHEQ staff including the trainee that updated the task done on previous week.
The huddle meeting this week cover about ppe expiry, sds availability, security acces and etc.
Furthermore, Ms Panimalar, SHE engineer (my industrial supervisor) has briefly describe the
SHEQ department, job scope, contribution to the company sales and sharing session along her
period becoming an environment engineer. I have also joined a safety meeting with Mr Andy
Cook, HSE Head of regional about safety update globally and safety level and achievement in
Malaysia. In addition, I have joined the safety meeting at Linde PJ Plant, the biggest cylinder
fillings in RSE. Despite the safety meeting, plan working safety inspection, risk hazard
assessment I have been given the chance to overview the cylinder fillings process at the plant
with the plant manager there. Last but not least, I have joined the National Stock Count with all
the Linde staffs in order to update the latest company assets specifically all the cylinders
produced. This indirectly taught me the cylinder asset management.
Reading of the week:
i.
ii.
iii.
iv.
v.
vi.
vii.

Argon separation process


Argon purification process
Public transport safety and security for commuters
Global Safety Assesment
Golden Safety Rule
Helium process operation
Feed gas supply system

MUHAMMAD ARIFF FATHI BIN MAWARDI


Degree of Chemical and Process Engineering(HOns)

LINDE MALAYSIA

WEEK 4
3rd August-7th August2015
Huddle meeting update for in cab camera review, contractor behavior assessment and etc.
Beside the completion of SDS pure gases, I have been assigned by Mr Mohsin Abd Karim, SHEQ
Central Manager to create Synergi account for all Linde Malaysia staff across the country
involving Sabah and Sarawak. In addition I have helped Ms Panimalar managing the solid
scheduling waste of Calcium Hydroxide on eswiss website, an official Department Of
Environment (DOE) website. Moreover, Sunway management collaboration with Jabatan
Bomba Dan Penyelamat have organized fire fighting training. The training covered both
theoretically and practically training as we experienced ourselves fight different types of fire in
various situations.

Reading of the week:


i.
ii.
iii.

Permit to work
Remote operating center
Auditing

WEEK 5
10th August-14th August 2015
For the week 5, the Huddle Monday meeting cover Corrective Action Reporting (CAR), Safety
Implementation Plan (SIP) and etc. Joined Contractor Safety Training Management for 2 nd time
as the new Project Site Safety Officer, Mr Ashraf had recently joined the team for new Linde
Plant in Geybeng, Pahang. Beside that I have helped SHE engineer, Mr Dinesh Raj creating the
emergency response plan for pinnacle tower in case of emergency. Take 5 session discussed
about safety at petro station. I also helped Ms Panimalar translating Lesson From Incident (LFI)
involving 8 cases in 2015. The LFI is done to find out the root causes of the accident and a
guideline to others in order to avoid the same incident happens again in the future. Mr Dinesh,
SHE engineer had asked my help for CAR overdue involving tonnage & PGP for CAR
consolidation. Assigned by Ms Panimalar to complete SDS for special gases.

Reading of the week:


i.
ii.
iii.
iv.

Maintenance, inspection & condition monitoring


CAR report
Materials and service management
Supplier quality and safety performance

MUHAMMAD ARIFF FATHI BIN MAWARDI


Degree of Chemical and Process Engineering(HOns)

LINDE MALAYSIA

WEEK 6
17th August-21st September
In this week, the Huddle meeting summarized about our company latest project located in
Geybeng, Pahang. Ms Eliani, SHE specialize lead the meeting as Mr Chan is absence due to
outstation. In the next day, I have joined General Induction training together with others 10 new
Linde staffs with various background and origin including Sabah, Serawak, Sri Lanka and India.
The training cover safety and quality induction, employee advantages on medical, work codes
ethics, inspirational experience sharing session by the management and etc.

MUHAMMAD ARIFF FATHI BIN MAWARDI


Degree of Chemical and Process Engineering(HOns)