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Industrial training is a one of the higher learning institutions for students to get used to
the actual working environment. As a Mechanical Engineering student, knowledge and work
skill is needed simultaneously. It allows students to practice the knowledge in the relevant field
and apply it based on their knowledge that lead to better soft skills. This report describes a
three-month industrial training that took place from 29th June 2015 to 18th September 2015 at
a local company named Sawit Kinabalu Apas Balung Mill, Tawau Sabah. Apas Balung Mill is
Palm Oil Mill operate under the auspices of Sawit Kinabalu Berhad. Main activity or
production of this company is to process Fresh Fruit Bunch (FFB) to Crude Palm Oil (CPO)
and Palm Kernel (PK). The product must undergo various test of quality test to control its
quality. Then, this product will be sent to Kunak Refinery for purifying process before it can
be sold to customers. Collaboration between Apas Balung Mill and Kunak Refinery is a long
term contract. 12 weeks of industrial training under supervision from Sir Mohamed Bin Hj.
Tagin (Workshop Supervisor), internship student was exposed to actual working culture and
industrial practice. Several tasks had been given based on main processing station at Apas
Balung Mill, which is Weighting Station, Loading Ramp Station, Grading Station, Sterilizer
Station, Thresher Station, Press Station, Clarification Station, Palm Kernel Station and etc. The
objective of the task is to improve our skills of engineers, theoretical and practical by
troubleshoot problem and finding solutions. The industrial training is reported as task were
carried out throughout the period.
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Table of Contents
ABSTRACT............................................................................................................................................ 1
1.0 INTRODUCTION ............................................................................................................................ 4
1.1 History .......................................................................................................................................... 4
1.2 Structural Of Main Activity .......................................................................................................... 5
1.2.1 Mill Production ...................................................................................................................... 5
1.2.2 Laboratory Activities ............................................................................................................. 5
1.3 Objective Of Practical Training .................................................................................................... 5
1.4 Scope Of Training / Schedule ....................................................................................................... 6
1.5 Company Organizational Chart .................................................................................................... 7
2.0 INDUSTRIAL ENVIRONMENT .................................................................................................... 8
2.1 Adaptation And Adjustment To The Industry .............................................................................. 8
2,1.1 Weighing Station.................................................................................................................... 8
2.1.2 Grading Station ...................................................................................................................... 8
2.1.3 Loading Ramp Station ........................................................................................................... 8
2.1.4 Sterilizer Staton ...................................................................................................................... 9
2.1.5 Thresher Station ..................................................................................................................... 9
2.1.6 Press Station ........................................................................................................................... 9
2.1.7 Clarification Station ............................................................................................................. 10
2.1.8 Sweco Vibrating Screen ....................................................................................................... 10
2.1.9 Crude Oil Tank .................................................................................................................... 10
2.1.10 Pure Oil Tank ..................................................................................................................... 11
2.1.11 Oil Purifier ......................................................................................................................... 11
2.1.12 Sludge Tank ....................................................................................................................... 11
2.1.13 Desander ............................................................................................................................ 11
2.1.14 Decanter ............................................................................................................................. 11
2.1.15 Sludge Seperator ................................................................................................................ 12
2.1.16 Vacuum Drier..................................................................................................................... 12
2.1.17 Crude Palm Oil (CPO) Tank .............................................................................................. 12
2.2 Practice Of Occupational Safety And Health Environment ........................................................ 12
3.0 INDUSTRIAL EXPERIENCE ....................................................................................................... 14
3.1 Task And Activities .................................................................................................................... 14
3.1.1 Grading Station .................................................................................................................... 14
3.1.2 Sterilizer Station................................................................................................................... 16
3.1.3 Laboratory Activiti............................................................................................................... 17
3.1.4 Analyse Machine Effiiency .................................................................................................. 19
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3.1.5 Workshop Activities ............................................................................................................ 19
3.1.6 Boiler Station ....................................................................................................................... 20
4.0 INDUSTRIAL PROJECTS............................................................................................................. 22
4.1 Overview ..................................................................................................................................... 22
4.2 Press Station ................................................................................................................................ 22
4.2.1 Repairing And Maintaining ................................................................................................. 22
4.2.2 Problem And Solution.......................................................................................................... 24
4.2.3 Mechanical Engineers Perspective ..................................................................................... 25
4.3 Skimmer, flange and pump base ................................................................................................. 25
4.3.1 CAD Drawing ...................................................................................................................... 25
4.3.2 Technical Skill ..................................................................................................................... 26
5.0 CONCLUSION ................................................................................................................................... 27
6.0 REFERENCE ...................................................................................................................................... 28
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1.0 INTRODUCTION
1.1 History
Apas Balung Mill located at Mile 24, Apas Balung road, Tawau, Sabah wholly owned
by Borneo Samudera Sdn. Bhd under the auspices of Sawit Kinabalu Berhad that operates in
Kota Kinabalu, Sabah. Apas Balung Mill was established in 1971 by two French engineers are
a crude palm oil and palm kernel processing plant with average processing is 60 metric tons
per hour. There are 135 workers at Apas Balung Mill, and the highest position is Mill Manager,
followed by Mill Engineer and assists by Assistant Engineer. Apas Balung Mill has 5 major
divisions which are Production, Laboratory, Workshop, Safety and Utility. Each division has
their own Supervisor to handle and supervise their workers. In addition, Apas Balung Mill
used the double line system during processing, which mean if any minor damage happened at
some machine, they have a backup to continue processing, but if the damage on major
components like conveyor, mill will stop processing because raw material which are FFB
cannot be transferred to another station for further processing.
Sawit Kinabalu Berhad (formerly registered) was formed when the State Government
of Sabah, in its continuing efforts to encourage the people of Sabah to assume a more
responsible role in the growth of the State, decided to corporatize the Sabah Land Development
Board (SLDB). The State Government believed that this will bring about greater efficiency
and effectiveness, thereby optimizing profitability and contributing directly to the economic
growth of the nation.
The Sawit Kinabalu Berhads Logo defines its corporate professionalism and
commitment to galvanizing growth. The prominent gold signifies strength and growth into a
new era of the Sawit Kinabalu Berhads diversified activities. The deep red shade of a ripe oil
palm seed represents the core activity of the Sawit Kinabalu Berhad in the palm oil industry
and symbolizes maturity and stability of its operation as it further embarks on a journey towards
greater excellence.
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1.2 Structural Of Main Activity
1.2.1 Mill Production
Apas Balung Mill main activity is to process fresh fruit bunch (FFB) to produce Crude
Palm Oil (CPO) and Palm Kernel (PK). To produce Crude Palm Oil (CPO) and Palm Kernel
(PK), a fresh fruit bunch (FFB) will be processed stage by stage according to their station.
Below are the main stations that have in Apas Balung Mill:
i. Weighing Station
ii. Loading Ramp station
iii. Grading Station
iv. Sterilizer Station
v. Thresher Station
vi. Press Station
vii. Clarification Station
viii. Palm Kernel Station
Laboratory act as quality control and quality assurance for Apas Balung Mill because
they will examine, analyze, and record oil quality every day. Besides, they also analyze the
mill efficiency covering the mill machine
Industrial training is one of the requirements for the Bachelor of Engineering (Hons)
Mechanical and also known as EM220 by Faculty of Mechanical Engineering at Universiti Teknologi
Mara (UiTM). The objective of industrial training is:
1) To Expose students to actual working culture and industrial practice in palm oil mill
industry especially in the engineering department
2) To allow students to extend their theoretical knowledge and practice in university use in
working environments.
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3) To motivate the students to work in a right way with good working attitudes and
professionalism to increase their employability potential.
Training schedule for practical trainee is same as other workers, which are from 7.00
am until 4.00 pm, Monday to Saturday. Below is the working schedule at Apas Balung Mill
and a summary of my activities during ten (12) week industrial training.
Days Time
Monday
Tuesday 7.00 am 4.00 pm
Wednesday (Rest 12.00 pm 1.00 pm)
Thursday
Friday 7.00 am 4.00 pm
(Friday Prayer 11.30 am 1.30 pm)
Saturday 7.00 am 4.00 pm
Week Activities
1 Study about Loading Ramp station.
2 Study about Grading system
3 Study about Sterilizer Station
4 Study about Thresher Station
5 Study about Press Station
6 Study about Clarification Station
7 Study about Palm Kernel Station
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8 Study about Boiler
9 Workshop Activities
10 Workshop Activities
9 Workshop Activities
10 Workshop Activities
11 Laboratory Activities
12 Laboratory Activities
SIR. MOHD ZAMRI BIN MOKRIN MDM. JELITA BUNGIN & SIR. BARY EYUL
SIR. FADLI BIN KASSIM MDM. DEWI NOOR BT MOHD ADNAN SIR ASLIE
WORKSHOP
BOILER
SIR MOHAMED B. HJ. TAGIN (MECHANICAL)
SIR. MUKRIM HJ. ASAS
SIR OMAR ALI OTHMAN (ELECTRICAL)
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2.0 INDUSTRIAL ENVIRONMENT
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2.1.4 Sterilizer Staton
Sterilizer station is a station to cook fresh fruit bunch (FFB) so that the fruits can be
detach easily from the bunch. Apas Balung Mill has four spherical sterilizer and each sterilizer
can accommodate up to 20 22 metric ton FFB. Nevertheless, spherical sterilizer cannot be
fully stocked because it requires air spaces to make evaporation process can be completely
done. Overall process to cook FFB in one spherical sterilizer is 61 minutes or 1 hour 1 minute
with average steam 2.80 bars or 40 p.s.i. Steams are used to break up the grafting between fruit
and the bunch. Before the FFB enter Spherical Sterilizer, it will pass through the FFB Hooper
with capacity 10 15 metric tons. FFB Hopper has the same design with truck dealer was
controlled manually with Hydraulic Power Pack to enter the FFB into Sterilizer. After 61
minutes, FFB will transfer to Sterilizer Fruit Bunch (SFB) conveyor by Mechanical Bunch
Feeder. The function of Mechanical Bunch Feeder is to control the FFB when entering
Sterilizer Fruit Bunch Conveyor regularly.
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100C and during processing Apas Balung Mill has fixed the temperature at 95C. In Digester,
there are five sets of expeller and impeller arm. The function of expeller arm is to blend the
fruit while impeller arm to push down the fruit to ease it entering the screw press. The capacity
of digester can accommodate up to 15 tons metric of FFB, and press can produce 15 tons metric
of crude palm oil depends on digester capacity.
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2.1.10 Pure Oil Tank
The function of this tank is to store oil from crude oil tank before it enters the purifier
machine. This tank can accommodate 6 metric tons of crude oil. There is steam coil in the
inner part of this tank, the function is to supply steam for oil to avoid it from solidified and the
steam temperature is about 70C to 85C.
2.1.13 Desander
The function of desander is to separate sand from the oil. This is important to avoid
sludge separator from damaged.
2.1.14 Decanter
Decanter function as oil filter to separate it from sludge. It have two types of disposal
which are cake (solid remaining after pressing) and oil. Oil from decanter will go into crude
oil tank for purification process while cake will be sold for fertilizer.
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2.1.15 Sludge Seperator
Sludge Separator used to extract oil from sludge. There is 5% oil in the sludge and we
dont want to waste any oil that we can get from any source. Oil will extract by rotating the
bowl of sludge separator with 5400 r.p.m.
1) Safety Helmet
a) Class C hard hats
i. Provide lightweight comfort and impact protection, but offer no protection from
electrical hazards
2) Safety Shoes
i. Impact-resistance toes and heat-resistance soles that protect the feet against hot
work surface. The metals insoles of some safety shoes protect against puncture
wounds. Safety shoes may also be designed to be electrically conductive to
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prevent the build-up of static electricity in areas with the potential for explosive
atmosphere or non-conductive to protect workers from workplace electrical
hazards.
3) Hearing Protection
a) Single-use earplugs
i. Made of waxed cotton, foam, silicone rubber or fiberglass wool.
ii. They are self-forming and, when properly inserted, they work as well as most
molded earplugs.
b) Pre-formed or molded earplugs
i. Individually fitted by a professional and can be disposed or reusable. Reusable
plugs should be cleaned after each use.
c) Earmuff
i. Require a perfect seal around the ear.
ii. Glasses, facial hair, long hair, or facial movements such as chewing may reduce
the protective value of the earmuff.
4) Eye Protection
a) Goggles
i. Tight-fitting eye protection that completely covers the eyes, eye sockets and the
facial area immediately surrounding the eyes and provide protection from
impact, dust and splashes. Some goggles will fit over corrective lenses.
b) Welding shields
i. Constructed of vulcanized fiber or fiberglass and fitted with a filtered lens,
welding shields protect eyes from burns caused by infrared or intense radiant
light.
ii. They also protect both the eyes and face from flying sparks, metal spatter and
slag chips produce during welding, brazing, soldering and cutting operations.
5) Gloves
a) Cover and protect hands from wrist to the fingers.
b) Save the users hand and fingers from unnecessary wound such as cuts, blisters,
splinters, skin punctures or heat and chemical burns.
6) Respirators
a) Protect the user from breathing in contaminations in the air, thus preserving the health
of ones respiratory tract.
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3.0 INDUSTRIAL EXPERIENCE
Throughout the training, trainee had been exposed with real situation with real problem
that needed to be solved as a real worker. Wide spectrum of work, ranging from doing
documentation works to being tasked to perform technical works. In this chapter, it will be
more on the production unit regarding on how to manage the mill efficiently without sacrificing
quality and quantity.
1) Grading must be done in the presence of the supplier or his representative like truck
driver or attendant.
2) Selected truck should depreciate their loading on a platform near the loading ramp.
Make sure the bunch in a flat condition which is not accumulating or layered.
3) Randomly, take 100 samples of the bunch and classified it to the following classes:
i. Ripe bunch
a) Reddish orange of fresh bunch and external layer of mesocarp is orange.
b) At least ten (10) fresh fruit socket detach from bunch and more than 50% fruit
still stick to bunch during the grading process. Bunch and detach fruit must
be sent to mill within 24 hours after reclaimed.
ii. Under ripe bunch
a) Has reddish orange or purplish red of fresh bunch.
b) Less than ten (10) fragmentary of fresh fruit socket during grading. Bunch
and detach fruit must be sent to mill within 24 hours after reclaimed.
iii. Unripe bunch
a) Purplish black colored fruits, covering more than 90% of the bunch surface.
b) Didnt have detached fruit of fresh bunch during grading.
iv. Over ripe bunch
a) More than 80% of the fruits in the bunch appear darkish red.
b) More than 50% of the detach fruit from the bunch, but at least 10% fresh fruit
still stick to bunch during grading.
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c) Bunch and detach fruit must be sent to mill within 24 hours after reclaimed.
v. Long stalk bunch
a) Fresh bunch that have stalk more than 5 cm measured from lowest bunch stalk.
Socket
No socket Less than 10 More than 10
Colour of Mesocarp
Orange Ripe Ripe Ripe
Yellowish orange Unripe Under Ripe Ripe
Yellow (Hard Bunch) Unripe Unripe Unripe
White (black Bunch) Unripe Unripe Unripe
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3.1.2 Sterilizer Station
Sterilizer is a crucial in gathering oil from the FFB, by using steam produce from the
boiler with certain temperature and pressure to break up the oil cell and detach the fruit from
its branch. If the sterilization process is incomplete, unbroken oil cell may result in oil losses
at high rate.
1) Removal of Air
a. Air is a bad heat conductor; with his presence heat from steam cannot be transfer
to sterilize the fruit completely.
b. To reduce oil oxidation because the oxidized oil is difficult to throw the colour
during deflection process.
2) Removal of Sterilizer condensate
a. To dispose excessive water and steam in Sterilizer
b. If condensate not disposes, water will stagnant and contribute to oil losses from
fruit.
c. Fruit will incompletely sterilize.
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No Equipment Quantity Load R.P.M Status Remark
1 Spherical Sterilizer 4 15kW 1450 F/R DOL Sterilizer fruit
2 Hoist 4 15kW - DOL Load / unload sterilizer door
3 Hydraulic Power 4 4kW 1440 DOL Controller the fruit into
Pack sterilizer
4 Compressor 1 7.5kw - DOL Open / closed steam valve
5 Mechanical Bunch 4 4kW 1440 DOL Controlled the fruit into SFB
Feeder conveyor
6 SFB Conveyor 2 18.5kW 980 DOL Deliver SFB into Auto feeder
7 Condensate 2 11kW 1460 S/D Pump out the condensate into
Recycle Pump condensate pit
8 Oil Recycle Pump 2 4Hp 1460 S/D Pump recycle oil to sterilizer
a) Apparatus
1. 2 units of 150 ml conical flask
2. 2 unit of 100 ml beaker
3. Stirring Hotplate
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4. Precisa 205AM-FR SCS weighing
b) Materials
1. Isopropyl Alcohol
2. Phenolplithalein Indicator
3. Sodium Hydroxide 0.098%
4. 0.1N Sodium Hydroxide
c) Procedure
1. Record the weight of empty 150 ml conical flask.
2. Put in the oil in the conical flask until the weight exceeds 5.00 g.
3. Heat isopropyl alcohol at stirring hotplate.
4. Put in five drops of Phenolplithalein Indicator and Sodium Hydroxide 0.098%
into isopropyl alcohol.
5. Heated oil sample.
6. Put in 50 mm mixed chemical at step 4 into the oil and 0.1N Sodium Hydroxide
until the oil colour change to reddish.
7. Record how much litres 0.1N Sodium Hydroxide enter into oil until the colour
change.
8. Calculate FFA content using formula
0.1 0.1 25.6
9. Repeat step 1 until 8 for second sample.
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3.1.4 Analyse Machine Effiiency
The purpose of this analysis is to make sure the efficiency of Nut Cracker exceeds 97% to
avoid a lot of kernel losses during processing.
a) Apparatus
1. Precisa 205AM-FR SCS weighing
b) Materials
1) Palm Kernel
c) Procedure
1. Take a kernel sample from cracked mixture conveyor
2. Weigh the sample until the weight become 1 kg
3. From that sample, separated Nut and Partial Cracker Nut (PCN) for weighing
process.
4. To get the efficiency of king cracker, the weight of 1kg sample minus with the
weight of Nut and PCN
Unplanned Breakdown
Maintenance Maintenance
Corrective
Maintenance Maintenance
Routine
Maintenance
Planned
Maintenance
Preventive
Maintenance
Predictive
Maintenance
Figure 3.8: Type Of Maintenance
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3.1.6 Boiler Station
Boiler is components used to produce steam for generating turbine rotor via alternator
and for sterilization process. There are two types of Boiler, which are Water Tube Boiler and
Fire Tube Boiler. In Apas Balung Mill, they used Water Tube Boiler because it can generate
steam faster than Fire Tube Boiler. In addition, steam pressure limit of the fire tube boiler lies
between 20 30 bar and the pressure limit of the water tube boiler is much more than the fire
tube boiler and is unlimited within the design limit. Water tube Boiler at Apas Balung Mill
used fiber and dry kernel as fuel for providing the heat.
Main component:
1) Boiler
Boiler is the heart of the factory, its the main component to generate steam to run the
factory. By physical appearance, rectangular in shape and full of water that will be
heated to transform water into steam. It has the same principal as boiling water in a
kettle at boiling point, but at a larger volume. In this mill, it has 2 steam boiler which is
water tube. During process, 1 boiler is sufficient to generate steam needed by this mill.
a) Boiler No. 5
- Capacity of 35 ton of water
- Maximum temperature at range 1000-2000 C
- Consist of 1000 pipe inside the boiler
b) Boiler No. 4
- Capacity of 20 ton of water
- Maximum temperature at range 1000-2000 C
- Consist of 700 pipe inside the boiler
2) Steam Turbine
Steam turbine function to create rotational motion that generates by steam from the
boiler. Boiler will produce high speed and pressurized steam into the steam turbine
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3) Feed Pump
Water pump function to pump water from storage tank into desired location. In this
mill, it consist of 2 types of pump which is pump that powered by electrical motors and
steam.
4) Condenser
Steam that enters the turbine will slowly change into liquid due to its kinetic energy
inside the water molecule decreasing. Because of that, steam that changes into liquid
will transfer into the condenser and most of the liquid will pass through a copper pipe
with full of cold water. This proses called heat transfer where steam changing into
water.
5) Storage Tank
Any resources needed to run the boiler are stored here. There are 2 types of storage tank
which is water storage tank and fuel storage tank.
6) Cooling Tower
Cooling tower function as water supplier for all of the tube inside the condenser. Water
that enter the condenser will be hot due to heat transfer. So, water pump needed to pump
the hot water into the condenser.
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4.0 INDUSTRIAL PROJECTS
4.1 Overview
As workers in workshop department, maintaining and repairing machine is our priority.
This department responsible to make sure that all machines work well and repair it if the
machine breaks down. Some modification might needed to ease the flow of the process or the
machine was too ancient to be used anymore. In this chapter, it will emphasize on workshop
and repairing machine suit as a Mechanical Engineering student.
If all of the press machines break down, this will be a major break down where all process
will be stopped. By using line production, we can avoid this by changing the line process with
the other line. In this mill, it has 2 lines with 3 press machine in each line. Major issues caused
by this machine are its screw press always breaks may be due to worn out because of long
usage or unnecessary object enter the press machine and stuck into the screw press that lead to
the screw to break in half. As an engineer, we should able to determine the problem and come
out with the solution. Troubleshooting should be done by observing the machine, leaking in its
bearing or amount of fibre suddenly decreasing is one of the signs to show that there is problem
about the machine. Below is the procedure about overhauling press machine.
1) For safety measures, open the pulley cover and v belt even if the fuse from the circuit
board had been turned off. Then, we can proceed by loosening all bolts on the press
body using spanner size 15, 21 and 24. Bringing adjustable spanner might come in
handy.
2) Using multiple chain block that attached to the ceiling, remove the press body and cone
section. Chain and belt might be used to attach the body with the chain block. Workers
should wear PPE such as gloves when handling the chain block.
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Figure 4.1: Cone section Figure 4.2: Press body
3) Screw press consists of Right Hand Side (RHS) and Left Hand Side (LHS), rotate RHS
anticlockwise and LHS clockwise to remove the screw press. Make sure that screw
press was hold using chain block. After that, screw cage can be lifted out using chain
block.
4) Remove the coupling cover so that both long shaft and short shaft can be removed.
Long shaft will connect with the coupling and using spur gear to rotate both shafts.
Each shaft will contain 3 bearings which are 2 roller bearings and 1 cone bearing.
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6) Clean the spacer and install new bearing with the same code number. Apply High
Temperature RTV Silicon Gasket Marker. This function as a gasket to avoid any leak.
After installing the coupling cover, refill the lubricating oil which is OMALA 320.
7) Install cone section and press body, tighten all the bolt securely. Run and test the
machine to make sure that its working fine. If any unusual sound or sign occurs,
recheck the machine so that there will be no more break down.
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Figure 4.5: Cutting the shaft Figure 4.6: Cutting the bearing
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4.3.2 Technical Skill
Both knowledge and technical skill is necessary in the engineering field. Lack one of this
component, might fail the purpose of the industrial training. After applying the knowledge
taught at university, learning the skill is compulsory at industrial training. The important
process of fabricating parts in this factory is by welding, cutting, milling and lathe machine.
Commonly, cutting was done using oxyacetylene. Having exposed to the real work experience
was scared for the first time, but after doing it frequently make me get used to it.
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5.0 CONCLUSION
The main objective of the industrial training is to provide an opportunity for undergraduates to
identify, observe and practice how engineering is applicable in the real industry. It is not only
to get experience on technical practices, but also to observe management practices and to
interact with fellow workers.
It is easy to work with sophisticated machines, but not with people. The only chance that an
undergraduate has to have this experience is the industrial training period. I feel I got the
maximum out of that experience. Also, I learnt the way of work in an organization, the
importance of being punctual, the importance of maximum commitment, and the importance
of team spirit. The exposure has definitely contributed a lot in developing me to become a well-
rounded future engineer and provide me the insights of employment and endeavour me to
undertake in the future.
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6.0 REFERENCE
1. Leo Finkelsten, jr., Pocket Book of Technical Writing for Engineer and Scientist, Third
Edition, McGraw, 2008 (ISBN: 978-0071259255)
2. Howard F. Gospel, Industrial Training and Technology Innovation: A Comparative and
Historical Study, Vol. 4, Taylor & Francis, 2010 (ISBN: 978-0415043403)
3. Howard K. Morgan, Industrial Training and Testing, BiblioBazaar, 2011 (ISBN:978-
1406713954
4. Lokesh Choudhary, Industrial Training and Education, Mittal Publication, 2007( ISBN: 978-
8183242363)
5. Diana Reep, Technical Writing: Principles, Strategies and Readings, Pearson Education
Canada, 2010 (ISBN: 978-0205721540)
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