latihan industri politeknik

1. BP CHEMICALS (M) SDN. BHD 12 JAN – 12 JUN INDUSTRIAL TRAINING POLYTECHNIC KUCHING SARAWAK

2. INDUSTRIAL TRAINING OBJECTIVE The purpose of industrial training is to expose Polytechnic students to the world of work so that they can relate theoretical knowledge with application in industry. From the Industrial training Program, the students will also develop skills in work ethics, communication, practical and theory. Furthermore, this Industrial training Program will establish close relationship between the industry and Polytechnic. The objectives of the training are as follows:

3. To integrate theory with practice To introduce students to work culture and industrial practices To give opportunity to students to work with industrial practitioners To expose students to potential employers To acquaint the Polytechnic students with industry and its programs Implement Health Safety and Environment (HSE) practices at workplace. Practical ethical professional work culture. Acquire skills in communication, management and team-work.

4. INDIVIDUAL OBJECTIVE The following are my objectives for having this industrial training: Expose to the new working environment To gain knowledge and exposure on equipments use in chemical plant To learn the technical knowledge To practically apply theoretical knowledge learned To enhance my leadership To improve my soft skills

5. Overview of BPCM

6. Overview of BPCM Located in the Gebeng Industrial Estate, 25 kilometers away from Kuantan town, on the east coast of Peninsular Malaysia, BP Chemicals Malaysia (BPCM) was established in this region to further strengthen BP's position as the world's largest Purified Terephthalic Acid (PTA) producer. PTA is the preferred raw material in textiles, video and audio films, soft drink bottles and engineering resins It is a wholly owned BP business unit. It operates a 600,000 metric ton PTA plant and this facility employs about 219 full-time employees and hundreds of internal and external contractors.

7. BPCM strives to be a world-class PTA supplier, committed to being a good corporate citizen by working towards its goal of no accidents, no harm to people, and no damage to the environment. To protect the environment, this PTA plant is equipped with advanced environmental protection facilities to ensure efficient waste treatment and minimal emissions. . Its community outreach program demonstrates its desire to have a measurable and sustainable positive impact on its surrounding communities

8. BPCM PRODUCT An aromatic acid Physically - White - Crystalline powder - Looks like powdered sugar Raw material; paraxylene (PX) - Colourless - Flammable liquid; sweet odour - Separated from a mixed xylene stream; from refining of petroleum

10. PROCESS OVERVIEW BPCM consist of two major sections which are Inside Battery Limit (ISBL) and Outside Battery Limit (OSBL). ISBL also divided into oxidation and purification unit for the production unit. OSBL is also divided into utility and waste water treatment. It is functioned to support the process of ISBL. Figure 1: Plant process overview

11. Overview of BPCM-PTA Process (Oxidation) FEED MIXING CRUDE TA TO STORAGE CRYSTALLIZATION Precipitation from Solvent OXIDATION REACTION SOLVENT PARAXYLENE CATALYST AIR STEAM TUBE DRYER Remove moisture FILTRATION Separation TA Solids & HAc

12. Overview of BPCM-PTA Process (Purification) FEED SLURRY PURIFIED TA TO STORAGE HYDROGENATION REACTION CRUDE TA PROCESS WATER CENTRIFUGING & FILTRATION Remove p-Toluics HYDROGEN STEAM TUBE DRYER Remove moisture CRYSTALLIZATION Precipitation from Solvent Crude TA Process Water

13. MAINTENANCEORGANIZATION

15. POWER DISTRIBUTION OF BPCM Step down ration from 132kV to 11kV 132kV 11 kV

16. Emergency generator of 3MW will supply electricity in any case of power failure.

18. EXPERIENCES ELECTRICALS Servicing motor and breaker Do trouble shoot for: lathe machine, welding , vacuum cleaner, wiring , breaker, contactor, VCB, lighting building, heater for lab, 11kV breaker, switch box starter, RCCB and MCCB. Cathodic protection system for pipeline and tank storage Install electrical equipment. Ex: socket, grounding for discharge Greasing motor Test run generator Electrical safety in hazardous area Electrical isolation

19. Instrument Do installation/calibration of pressure transmitter Metler Toledo Training- new sensor Calibration of pressure switch

20. Electrical tools Cable detector Power quality Multi meter Avo meter

21. Tripping tools Clamp meter Cathodic protection tools

22. Insulation tester Pipe bending

24. Hand pump

26. Thermal overload test

28. switching protection clothes

30. Trainee Activities Service Breaker and Motor

31. Working at panel motor control center

32. 415V Circuit breaker and motor contact Current transformer Thermal overload Start &stop indication light Circuit breaker Reset button

33. Contact service

34. Breaker test

35. Breaker test bypass

36. Breaker test in ON position

37. Jumper to breaker testing equipment

38. Step for Breaker service Check all connection and cable sleeve Phase inlet & outlet stab connectors Neutral inlet outlet stab connectors Aux contact Earth contact Contactor terminals Timer terminal Fuse terminals Current transducer terminals Terminals outgoing (compartment) Check abnormality patended supports Service contactor Lubricant moving mechanism Function test rack in test pos. limit switch

39. Function test remote off selector switch Function test overload relay 500V megger at close position RE,YE,BE,RN,YN,BN, RY,RB,YB Resistance check at open and close position

40. 6.6kV breaker

41. Breaker part repairing

42. 11kV Breaker operating Repair in progress

43. Example motor

44. INDUCTION MOTOR

45. ROTOR & WINDING

46. MOTOR WINDINGS TEST Motor windings resistance check Motor windings insulation test with earth 415v(500V), 6.6kV(1kV) Lubrication see rating plate Clean motor head exchange cooling fan

47. Generator test run Procedure to start

48. 3mW generator procedure Check air compressor Check generator and engine room Check battery panel Check master control panel at substation Check generator control panel Check & record meter reading Start more than one hour Stop generator

49. Overview of generator

50. troubleshoot Wiring installation Breaker failure cannot energized. Vacuum cleaner ,one motor carbon brush failure Plug direct on line starter

51. Repair Welding set Vacuum Wring installation Plug and socket

52. Special project

53. Replaced sport light port storage

54. VSD install cable

55. Soft starter install cable

56. Cathodic protection pipeline and tank storage Cathodic protection effectively protects underground or submerged metallic structures through the use of a negative potential applied by an external source to the structure. Commonly, once the structure has been made sufficiently negative, environmental corrosion (soil or moisture) is resisted. The method is typically applied to iron or steel structures such as underground pipelines, storage tanks, the interior of water storage tanks, ocean pilings, and electrical transmission towers. Buried steel structures will revert back to their natural state as an iron oxide without proper intervention.

57. Example cathodic protection potential

58. Test point and cathodic panel

59. Aircond part Replace compressor ac 132kV substation

60. Instrument part Calibrate Install training

61. instrument Calibrate pressure switch use SFCand hand pump transmitter Install transmitter analogue at shipping use for transmit pressure nitrogen gases to analogue meter. Training new pH sensor from metlertoledo

62. calibration

63. Conclusion Industrial training program in BPCM had given opportunities to trainee to prepare himself as future E&I technician. BPCM is one of the best company/ plant for trainee to have exposure on chemical production plant industry. 6 months period is the most suitable duration period for industrial training because it has enough time to maximize the learning process. BPCM has a lot of employees who is willing to help to make this industrial training program a success.

64. Thank You For all STAFF E&I MAINTENANCE Mr LIM SU SENG, Mr AZMEE, MR AZMI, Mr HARRIS, Mr MOHD NOOR, Mdm RUZAIMAH, Mr AMRAN, Mr HJ Masri, MrWan Rozman, MrMubin, MrMustapha, MrTana, MrBurhani , MrSaadudin, MrHj Hakim, MrZulhijah, MrAsean, MrImran, MrSoleh. Mentor,( Mr Wan Rozman,MrAzmi and MrMubin). CONTRACTOR ESPECIALLY WARGA HIKMAT (Mr MUBIN, Mr PAKYA, Mr HARITH, MrALI) UTP TRAINEE INTAN