Isi Kandungan

UNIVERSITI TEKNIKAL MALAYSIA MELAKA___________________________________________BMFA

1.0 INTRODUCTION 1.1

Briefing to Industrial Training Industrial Training is a scope which is a syllabus to the each student in IPTA level

weather for diploma or degree and UTeM also one of them. It is compulsory for an UTeM student to pass the industrial training before being awarded the degree or diploma in their course. Each student must complete the whole duration period i.e. 20 weeks for Degree course and 10 weeks Diploma course and not permitted to end the training earlier than the specified. The main of objective of Industrial Training is to expose to actual working environment whereby students will encounter new problems and challenges.

1.2

Objective of Industrial Training 1.

To expose students to actual working environment soon.

2.

To enhance students knowledge and skill.

3.

To instil the qualities of integrity, responsibility and self-confidence.

4.

To expose students to safe practices and regulations in the industry.

5.

To instil spirit of teamwork and good relationship between student and fellow workers.

6.

To assess student ability and competency in their preparation to join the workforce upon completion of their studies in UTeM.

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA___________________________________________BMFA

1.3

1.4

Objectives of this report 1.

To document the all activities during industrial training.

2.

To prove to lecturer that the student have complete the industrial training.

3.

To generate new idea to resolve the problem.

Important of Industrial Training to Student Industrial Training is one of the aspects which importance to the student to instil

higher sprit and confidence level in their self when joins in actual working environment soon. Beside that, the student will make comparison what they learn at UTeM with the jobs while industrial training. The will know whether what they studies is learn or not and it most benefit for their experience. During industrial training, student needs to instil the qualities of integrity, responsibility, open minded, inquires and self-confidence will in their self it will make student to done the works perfectly and smoothly. Relationship student and employee need to close. The student can ask anything what they not understand easily. So the student can get more information for their knowledge and experience. To the students who were passed for industrial training they will feel difference in their self. With the skill and experience which they learn during industrial training will make them more confidence to join in what ever they do because the skill and experience very benefit to them when join in actual working environments soon.

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA___________________________________________BMFA

1.5

Scope of Industrial Training During industrial training I get 1. Learn how job in oil industry. 2. Improve skill of welding and cutting. 3. Learn the work of workshop. 4. Get knowledge in maintained field. 5. Get knowledge about how many component/parts. 6. Learn about calculation in engineering field.

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA___________________________________________BMFA

2.0 ORGANIZATION BACKGROUND 2.1

Company History

The era of

the

Figure 2.1 Aerial view of the Ulu Bernam Oil Palm Factory discoveries brought the people of Western Europe face to face with the ancient cultures of the old world. Perhaps it is a legacy of those events, strengthened by an inherent urge of much greater antiquity that moved man of talent and initiative to seek the wonders of the East. During the year 1885, the founder of United Plantations, Mr. Svend Aage Westenholz left Denmark for the Kingdom of Siam upon graduation as a civil engineer. Mr. Westenholz, who had served in the Danish Army as an Artillery Officer, joined the Siamese Forces together with other Danes living in Bangkok when a French Navy Force tried to subdue the Siamese, shortly after his arrival in Siam. The French Navy Group was forced to retreat due to the fierce resistance. As a consequence, the Danes won much goodwill from H.R.H. the King of Siam and the Siamese people. Mr Westenholz and others were given concessions to supply electricity to Bangkok by 4

UNIVERSITI TEKNIKAL MALAYSIA MELAKA___________________________________________BMFA

the creation of a company called Siam Electric. This in turn caused Bangkok to have a tramway system before it was introduced in Copenhagen. The East Asiatic Company was given the concession of the teak wood extraction and rice export from Siam. A Danish naval officer, Commander Richelieu, was promoted to Commander in Chief of the Siamese Navy. These were the early days of the great economic advance of the West. Around the turn of the century, the rubber industry was in its infancy and interest in rubber planting in Malaya was growing In 1906, Mr. Westenholz found the opportunity to realize a plan close to his heart and the Jenderata Rubber Estate of 809 hectares was established in Lower Perak, near Teluk Anson. This initial plantation venture in Malaya, the Jenderata Rubber Company, was followed some years later by the establishment of Corner, Raja Una and Westenholz Brothers Coconut Estates on the Selangor Bank of the Bernam River, opposite to Hutan Melintang. Finally during 1917, all were merged into United Plantations Limited. Mr. Westenholz retired in 1911 and was succeeded in Bangkok by his younger cousin, Commander William Leannart Grut, who likewise elected to spend his working life in the East in preference to naval career in Baltic waters. In view of the successful planting of 8 hectares of oil palm at Sungei Bernam Estate during 1918, Commander Grut was delighted to meet with a Dutchman, Mr. Blumendall when he returned from leave in Europe. Mr. Blumendall managed to awaken Commander Grut’s interest in oil palms, wherefore Mr. Blumendall was appointed Planting Advisor when Commander Grut acquired 2,428 hectares situated 60 kilometres, up the Bernam River, which in turn made Commander Grut the founder of Bernam Oil Palm, one of the pioneers of the

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Malaysian Palm oil Industry, which coincided with Guthrie’s and Socfin’s ventures into the cultivation of oil palms. It was Tan Sri Dato’ Seri B. Bek-Nielsen’s privilege to the employed by Bernam oil Palm Ltd. as an Assistant Engineer during 1951 – at the height of the Emergency. Tan Sri Dato’ Seri B. Bek-Nielson was posted at the Ulu Bernam Oil Mill, which is 60 kilometres up the Bernam River, totally surrounded by jungle. Security protection was then provided by British and Malay army personnel. During 1966, United Plantation Ltd. and Bernam Oil Palm Ltd. were amalgamed into United Plantations Berhad. United Plantations Berhad was sold to Kumpulan Fima under New Economic Policy and Malaysianisation process. Danish shareholders kept 25% of the company. Approx. 4,047 hectares of plantation land were acquired which resulted in United Plantation’s acreage reaching approx. 27,519 hectares. The Danish group Aaehus Oliefabrik (now AarhuKarlshamn AB), a leader in the global speciality fat complex, acquired Kumpulan Fima’s controlling stake in United Plantations and emerged as a major shareholder. The acquisition of United International Enterprises (M) Bhd, 10,522 hectares of plantations, on 25th March 2003 resulting UP’s land blk reaching approx. 38,041 hectares. Socfin’s Lima Blas Estate was successfully acquired by United Plantations Berhad which brought the Company’s total land bulk to 40,874 hectares and has thereby become one of the key players in the Malaysian palm oil industry. On 25 th April 2006 UP announced acquisition of 2 Indonesian plantation companies, namely: PT. Surya Sawit Sejati and PT. Mirza Pratama Putra. Upon the acquisitions, the company will have access to approximately 30,000 hectares of land in Indonesian. The land will be developed over the next 6 to 7 years.

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA___________________________________________BMFA

On 27th April 2007 UP announced that it had entered into a new conditional Master Agreement with the shareholders of PT Surya Sawit Sejati and the existing shareholders of PT Sawit Seberang which will, upon completion, result in the Group having access to approximately 40,000 hectares of plantation land in Indonesia. 2.2

Company Facts The company’s principle business activity is in the cultivation and processing of palm

oil, coconut and other plantation crops in a sustainable manner. Its subsidiary companies are engaged in several downstream activities such as; processing palm oil; and manufacturing; packing/ distributing of end products in the form of cooking oils, edible oils, specialty fats and soap products. United plantations Berhad is one of the most efficiently managed, eco-friendly and integrated plantation companies in Malaysia and is well known globally for its best agricultural practices and high quality standards. In Malaysia UP’s total Land banks consist of approximately 40,874 hectares. The main focus in cultivation of oil palm (90%) and coconuts (10%). In Malaysia, United Plantations Berhad operates 6 Palm Oil Mill and the Unitata refinery, a subsidiary that has been cooperating for a number of years, on a joint venture basic, with AarhuKarlshamn AB; a leader in the global speciality fats sector. With the acquisition of two Indonesian plantation companies in 2006 the total hectare in Indonesian will be approximately 40,000 hectares which is expected to be developed over the next 10 years. Development is progressing as planned. United Plantation Berhad possesses considerable know-how in plant breeding, agronomy, and micro-propagation through its own R&D facilities for the development of new and improved plan ting materials as well as improved crop husbandry practices.

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This has resulted in United Plantations Berhad being recognized as one of the highest yielding, cost-competitive and innovative plantation companies in Malaysia. United Plantations Berhad’s connection with the AarhuKarlshamn group is seen as a vey important business strategy in providing traceability and thereby the ability to control the raw material from the agricultural source to final product-contrary to many other refineries, who have to source their raw materials from the open market.

2.3

Organization Chart

Table 2.2 Organization Chart

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2.4

Organization environment policy To conduct our agricultural business in the best principles of agriculture and in

harmony with the natural environment. •

To produce quality palm oil, palm kernels, coconuts and their derived products to the total satisfaction of our worldwide valued customers.

•

To produce elite oil palm, coconut and banana planting materials with proven yield potential.

•

To value our human resources and to continuously strive to provide a conductive and safe environment at the work place.

•

To adopt proven and sustainable agricultural practices those are environmentally compatible.

•

To promote the conservation and development of biodiversity within our group of plantations.

•

To continuously work towards a dynamic and innovative waste management and utilisation system aimed towards achieving zero waste.

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2.5

Occupational safety and health policy We at United Plantations Berhad are committed to secure the safety and health of all

our employees at work. In the operation of our activities, we strive to maintain a safe and healthy working environment for our employees, customers and the public. We value our work place Safety and Health as of paramount importance to the well being of all our employees and our respective Managers/Heads of Departments are responsible in implementing this policy. In striving to secure a safe and healthy work environment we shall: •

Devote our continuous efforts to accident prevention

•

Provide continuous training and supervision to all categories of employees to build and promote a safe and healthy work environment in full compliance with legislative requirements.

•

Equip and train employees to use appropriate protective equipments and to develop a health and safety conscious citizen.

•

Develop a cultural of individual responsibility and accountability for the employee’s own well being as well as those of the personnel and facilities under their control.

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA___________________________________________BMFA

•

Required contractors working on our behalf and supplier doing business with us to adhere to the Safety and Health regulations and standards.

2.6

Quality Policy It is the Policy of United Plantations Berhad to produce Palm Oil and related Second

to None in Quality. Our Quality Philosophy includes:•

Upholding the name and reputation of United Plantations as a top producer of top quality palm producers.

•

Nurturing a diligent work force.

•

Initiating and innovating positive, progressive work ethics and methods.

•

Training of personnel is the key to upgrading our skills.

•

Ensuring only the best quality palm products are produces, for customer’s needs.

•

Decisive efforts in Research and Development continuously to improve our working methods.

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA___________________________________________BMFA

3.0 TRAINING ACTIVITIES This topic will describe about my training at 5 different sections during industrial training. First month at fruit cages section, where I learn about how to use cutting torch and welding set. The machine involve are oxyacetylene cutter and arc welding. Second month at Locomotive section. Here I learn about loco operation, which involve hydraulic pump and motor; 2 speed gear box and 4 and 6 cylinders Volvo Deutz engine. Third month at palm oil mill machinery section, where I learn about high speed gear box, low speed gear box, blower fan, reduction gear box, heavy machinery, etc. Forth month at vehicle mechanics section, where I learn about diesel engine, tractor, heavy machinery, etc. Final month at machinery section. Here I learn how to use 4 jaw lathe machine, shaping machine and drilling machine. 3.1.1WEEK 1 1. Welding under wagon wheel 2. Repair fruit cages 3. Repair rail in marshal field 12

UNIVERSITI TEKNIKAL MALAYSIA MELAKA___________________________________________BMFA

3.1.2WEEK 2 1. Repair fruit cages 2. Repair rail in marshal field 3.1.3WEEK 3 1. Repair fruit cages 2. Repair rail in marshal field 3. Assemble Volvo Deuz engine 4. Make stopper in steriliser

3.1.4WEEK 4 1. Repair fruit cages 2. Repair rail marshal field 3. Weld locomotive body 4. Public holiday 3.1.5WEEK 5 1. Tighten belt 2. Transfer engine 3. Tighten drive chain

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA___________________________________________BMFA

4. Repair exhaust muffler 5. Change water line 6. Service locomotive 7. Change locomotive paint 3.1.6WEEK 6 1. Dissemble under wagon wheel 2. Tighten belt 3. Assemble hydraulic pump 4. Dissemble gear box 5. Repair fruit cages 6. Repair trailer 7. Make keyway in sprocket 8. Service locomotive 9. Applying Gris on join for shovel

3.1.7WEEK 7 1. Repair hydraulic pump 2. Assemble gear box

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA___________________________________________BMFA

3. Public holiday 4. Dissemble piston, head and cylinder 5. Dissemble gear box 6. Service locomotive 7. Check oil level in tractor 8. Check hydraulic pump 3.1.8WEEK 8 1. Assemble crane 2. Assemble coupling for shovel 3. Public holiday 4. Check leakage on hydraulic line 5. Service locomotive 6. Repair fruit cages 7. Repair rail at marshal field 3.1.9WEEK 9 1. Assemble coupling of shovel 2. Change hydraulic line 3. Dissemble under wagon wheel

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA___________________________________________BMFA

4. Change tyre of shovel 5. Assemble gear box 6. Repair fruit cages 7. Repair silencer 8. Change oil line 9. Assemble locomotive 10. Service locomotive 11. Change hydraulic oil 12. Repair counter weight on locomotive 3.1.10WEEK 10 1. Check steriliser inlet and outlet valve 2. Repair centrifugal water pump 3. Check chain of the auto-feeder 4. Tagging the machine 5. Service shoot blower for the boiler 6. Public holiday 7. Check fruit elevator 8. Remake pipe line for steam

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA___________________________________________BMFA

9. Change overhead crane cable 3.1.11WEEK 11 1. Repair fruit elevator 2. Dissemble drive shaft of the fruit elevator 3. Clean air flow controller for the boiler 4. Dissemble dynamo of the steam turbine 5. Check oil purifier 6. Dissemble oil purifier 7. Make electric motor cover 8. Change motor of the fruit bouncer

3.1.12WEEK 12 1. Make motor cover 2. Weld stainless steel piped 3. Public holiday 3.1.13WEEK 13 1. Change wheel of over head crane 2. Make new table for motor and pump

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA___________________________________________BMFA

3. Weld plate on marshal field 4. Make cover for fruit elevator bearing 5. Assemble ripper mill 6. Make motor cover 7. Assemble blower fan for the boiler 3.1.14WEEK 14 1. Modified kernel silo 2. Assemble hydraulic top cover 3. Dissemble IPTO clutch 4. Dissemble fuel pump 5. Repair IPTO clutch 6. Public holiday 3.1.15WEEK 15 1. Dissemble rear axle housing 2. Assemble rear axle housing 3. Check fuel line on bus 4. Assemble radiator 5. Service tractor

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA___________________________________________BMFA

6. Assemble IPTO clutch 7. Check hydraulic line 3.1.16WEEK 16 1. Assemble fuel pump 2. Service tractor 3. Change cable of the rudder for mini ferry 4. Change cable of the ramp 5. Assemble ball join 6. Dissemble brake pout 7. Repair rear axle housing 8. Public holiday 9. Assemble brake pout 10. Change transmission oil 3.1.17WEEK 17 1. Clean engine part 2. Assemble engine 3. Test run the engine 4. Service tractor

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3.1.18WEEK 18 1. Test run the engine 2. Change rocker arm 3. Put engine back in the pick up

3.1.19WEEK 19 1. Service the truck 2. Tighten the engine head bolt 3. Make keyway for sprocket 4. Make keyway on shaft 5. Dissemble tractor engine 3.1.20WEEK 20 1. Make oil seal cover 2. Make stepper for oil seal 3. Make shaft 4. Finish industrial training

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3.2

FRUIT CAGES & RAIL LINE IN MARSHAL FIELD

Objective of training in this section •

Function and used of the oxyacetylene cutter

•

Function and used of the arc welding machine 3.2.1

Fruit Cages

Most of the plantations transport the fruit bunches from the field to the mill using tractors or truck. At United Plantations they used unique light railway system to transport the fruits to the mill. All the fruit bunches will be filled into the fruit cages and transported to the nearest palm oil mill. The fruit cages can be filled up to 2.5 tans of fruit bunches. Before the fruit bunches been cook by steam in steriliser, the fruit bunches are filled full in the fruit cages. 21

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At this section I was assigned to repair the fruit cages that been serious damages. At this section I work with Mr. Muniandy and Mr. Murali. The main objective I was assigned to this section is to learn about use of oxyacetylene torch cutter and arc welding. The tools involved in this fruit cages repair section are:1. Oxyacetylene cutter 2. Arc welding machine 3. Welding rod MS 6013 4mm Major damage always occurs on the bottom part of the fruit cages and the lifting part. This happen because the fruit cages get smashed on to the under wagon during the transferring from other under wagon. The thickness of the plate also decreases day by day because of the corrosion of the weather and the fruit bunches. If the plate that places the lifting ring was tear apart than that plate need to be replaced with the new one. First step is to cut the lifting ring off the old plate. It was cut using the oxyacetylene cutter around the ring. In side the lifting ring also need to be cut. Then the lifting ring is grinded smoothly. On the new plate, the lifting ring is set at the centre of the plate. The lifting ring has to be centre. If not when the fruit cage is lifted by the over head crane it will not stable and well balance. The welding is done using the arc welding. The weld needs to be very tough and strong. The weld should able to lift about 2.5 tons of fruit bunches or more into the air. After that the plate is weld to the fruit cages. The weld should be done inside and outside. They use arc weld to weld the plate into place. After that the fruit cage is turn over. On the bottom the lifting plate and the bottom plate is weld together. All the plate is made of

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mild steel. The thickness of the plate is 3/16 inches. Only the bottom plate holes of diameter 1 inch. Holes plates are used only on the bottom of the fruit cage because it allow the rain water to be drain out of the cages. If there are no holes then fruit bunches will get rotten and will produce very low quality crude oil and kernel. The second reason is to allow the steam to follow trough it. By this way all the fruit can be cooked well in a short amount of time.

Figure 3.1 Damaged Fruit Cage

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Figure 3.2 Repaired Fruit Cage

3.2.2

Rail Line

Rail line is used to move the fruit cages filled with fruit bunches in marshal field. This rail line is cover all over plantation field. It mean that the under wagon can keep on moving no matter where it is on he field. There are 7 sterilisers used in this factory. It mean that in this marshal field there are 7 rail lines for sterilisers, 2 for incoming fruit cages from field and one for out going fruit cages. There also many junctions connect all this rail line together. The rail line junctions always get damages because the factory run 24 hours per days accepts Friday. The damages occurs because of the under wagon wheels and corrosion that occur. Most of the damages occur when the under wagon run off the rail line at the junction.

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At the junction there are 2 moving rail which help to navigate the under wagon. When the under wagon run off the rail line, the wheel put more that 2 tons of pressure to the bolt that connect the rail line. As days goes by, the bolt and nut will get cut by the under wagon wheel. So every week the junctions need to be repaired to help smoothen the operation of the factory producing crude oil and kernel shell. Sometimes not only the rail line junctions get damaged but the stopper at the end of the rail line in the steriliser get ripped off. The stopper function is to stop the under wagons from slamming the end of the steriliser. However it not designed to stop pressure more that 20 tons. The workers always pushed the under wagons to fast in to the steriliser until the stopper get ripped off the rail line. The tools involve in repairing the rail line and stopper are:1. Oxyacetylene cutter 2. Arc welding machine 3. Cord grinder First the old the rail junction will be cut off from it base. Then the base is cleaned and grinded. A new rail bar is measured at the right length and cut with the oxyacetylene cutter. After that the rail bar placed on the base and bolted to the rail line. The bolt can’t be tightening too much because the rail bar should be moveable by human force. The bolt and nut are weld together to prevent it from loosen. The same steps are taken when repairing the stopper in the steriliser. First the stopper is removes from it base. The base is cleaned from any weld scar by melting away the scar using the oxyacetylene cutter. Then the base is grinded with the cord grinder. After that a new

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stopper is made using L bar with dimension 5 inches (h) X 3 inches (w) X 1/4 inches (t) X 18 inches (l). The new stopper is then fixed to the end of the rail line in side the steriliser. The new stopper weld securely to the rail line using the arc welding machine and stainless steel rod. Now the steriliser can be operated for steaming the fruit bunches.

Figure 3.3 new stoppers welded inside the steriliser

Advantage •

Get instil spirit of teamwork and good relationship

•

Get expose student to actual working environment

•

Get knowledge and technique of using oxyacetylene

•

Get knowledge and technique of using arc weld

Disadvantage 26

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•

Really hard work

•

Back breaking job

Suggestion •

All the welded part or component need to be painted to avoid corrosion

•

Always wear protective gear

3.3

LOCOMOTIVE SECTION

Objective of training in this section •

Function and used of the hydraulic system in transportation system

•

Function of gear box 27

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•

Locomotive operation system

Monthly maintenance of the locomotive:•

Engine oil

•

Engine oil filter

•

Hydraulic oil filter

•

Air filter

•

Fuel filter

•

Chain tension

•

Battery water level

Correction maintenance of the locomotive:•

Engine of the locomotive

•

Hydraulic pump

•

Hydraulic motor

•

Hydraulic host

•

Hydraulic gear box

•

2 speed gear box

•

Locomotive frame 28

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United Plantation Berhad has unique light railway system that stretches over 500 kilometres. This company used diesel locomotive to pull a train of fruit cages containing fresh fruit bunches. The fresh fruit bunches are filled into the fruit cages in the field. Then the fruit cages are pulled to the oil palm extracting mill. This system has existed since 1930’s since this company was opened. There are two types of locomotive that been used in this company. One is driven by hydraulic power motor and another one use two speed gear including reverse. Both of the system used four pistons Volvo Deutz Engine. This type of engine is air cooler type. There are also 6 pistons Volvo Deutz Engine. And lastly use normal Ford engine. Four pistons Volvo Deutz engine is the one that use widely in this company. However they use chain to transfer the energy from the gear box to the wheels. The locomotive are capable of pulling 30 fruit cages when fully loaded each weight 2.5 tons. When calculate for total load:30 X 2.5 tons = 75 tons This locomotive really power full. The locomotive is serviced every month to make it at it top performance.

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Figure 3.4 Locomotive 3.3.1

LOCOMOTIVE REASSEMBLE At this section, I learn to completely how to overhaul the Volvo Deutz Engine. Before

starting any assembly all the part are soaked in oil to remove any impurity. Firstly the piston is connected with piston rod. There should be some gap for the piston to move at the piston rod. After that crank shaft bearing is installed. The bearing is made of aluminium and not like any bearing. It shape like a semicircle plate made of aluminium. The bearing will eventually wear off. Then crank shaft is fitted in. The bolts are tightening about 70 lbs/in. The main objective of using torck wrench is that all the bolts are tighten even and to avoid any damage on the tread. After that each piston are fitted into the cylinder. Then the cylinder and piston installed to the engine block. The piston rod is connected to the crank shaft. Aluminium bearing is installed between the crank shaft and piston rod. The piston rods bolts are tighten at 50 lbs/in. The flywheel is fitted to make the next step easier. The cam is installed into the engine block. Before installing part each of them are applied a film of lubrication oil. At the end of

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the engine block the idle gear is installed that connect the crank shaft and cam shaft. The timing of the gear has to be precise. After that fuel pump gear is installed. The front is fitted into the place. Oil reserve cover also fitted to the place. After that the engine are place on the oil reserve cover. At this stage, rocker rods are inserted until reach the cam shaft at the bottom. Then the engine head are mounted on top of the cylinder. The engine head tighten at 90 lbs/in.

Figure 3.5 Engine block fitted with piston rod and gear system Before proceed to next step the fuel pump is installed into the place. All the bolts tighten as hard as possible. The nozzle and fuel line from fuel pump to nozzle installed. The flywheel turned to see any disturb in rotation of the engine. Then the rocker installed and relief gap set at 0.12mm for each valve. Finally the blower, starter and belt fitted to the engine. The engine is ready to be mounted to the locomotive frame. However it still missing hydraulic pump. A new mounting cover is made to mount the hydraulic pump to the engine at

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the flywheel. The hydraulic pump is fitted to the cover and then to the engine. The complete engine is ready to be mounted to the frame.

Figure 3.6 Engine mounted to the locomotive frame This locomotive also need hydraulic motor pump to drive it. Firstly the bearing at the gear box change with the new one. Then the hydraulic motor pump is fitted to the gear box. Finally the gear box is fitted to the 2nd secondary frame. Then it fitted to the primary frame. After 1st secondary frame fitted, the engine is mounted to the locomotive frame. Hydraulic host connect the hydraulic pump and hydraulic motor pump and actuator. The locomotive is now can be used.

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Figure 3.7 Hydraulic motor fitted to the gear box

Figure 3.8 Fully assembled locomotive

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Advantage •

Understand the operation of the locomotive

•

Understand the function of hydraulic system

•

Understand the function of gear box

Disadvantage •

Short of time

•

Did not able to learn more about the air coolant type engine

Suggestion •

Need more time

•

More source about the air coolant type engine

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3.4

FACTORY SECTION

Objective of in this section:•

Learn about high speed gear box

•

Learn about low speed gear box

•

Learn about blower fan

•

Learn about reduction gear box

•

Learn about heavy machinery

•

Learn about factory operation in producing product

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3.4.1

Operation of Palm Oil Mill Sterilization

Effluent Treatment

Threshing

Sludge Centrifugation

Turbine

Digestion & Pressing

Clarification

Boiler

Depericarping

Oil Purification

Nut Drying

Oil Dehydration

Nut Cracking

Release to River

Crude Oil Palm

Winnowing

Kernel/Shell Separation

Shell Side in Hydro 36

Kernel Drying

UNIVERSITI TEKNIKAL MALAYSIA MELAKA___________________________________________BMFA

Figure 3.9 Flowchart of Fresh Fruit Kernel

Bunches Process

3.4.1.1 Fruit Bunches Reception Fresh fruit bunches arrives from the field as bunches and loosen fruit. The fresh fruit bunches arrives in fruit cages. It then weighted on a scale so that quantities of fruit arriving at the mill may be checked.

Figure 3.10 Fresh Fruit Bunches been brought to the factory

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3.4.1.2 Steriliser Fresh fruit bunches in the cages will push into steriliser by using skid steer loader Cater Pillar 910. There are 7 sterilisers in the factory. One steriliser can fill 7 fruit cages or 17.5 tons in one time for sterilization process. Here the fresh fruit bunches will cook by steam at pressure 40 psi which was supply from boiler to steriliser. The objective of sterilization is:•

To remove the fruits from bunches with easily while in thresher

•

To stop appeared enzymes in Free Fatty Acid (FFA) so get stop increase FFA

•

To stop oil from fruit while press processing

•

To avoid the kernel damage in cracking process

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Figure 3.11 Sterilisers

3.4.1.3 Over Head Crane Then fresh fruit bunches will pull out from steriliser by using skid steer loader Cater Pillar 910. There are 4 over head cranes in this station. Over head crane will pick up cages to transfer fresh fruit bunches into Auto Feeder. If over head crane get transfer the fresh fruit bunches in a cages in 2 minutes, so:1 cages = 2.5 tons = 2 minutes If 1 hour (60 minutes) =? tons 2 minutes

= 2.5 tons

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60 minutes

= 75 tons

From this calculation, we know that capacity of factory is 75 tons per hour.

3.4.1.4 Auto Feeder and Thresher After sterilization the sterilized fruits are threshed to remove fruit from bunches. Sterilized bunches are fed continuously into the rotary drum which is a made of channel bars which run longitudinally along the drum and that drum is diameter 6 feet or 1.8 metre and rotate 1440 rpm. The bars are so positioned as to allow fruit to past through but not the stripped empty bunch which is conveyed out of the thresher. Some empty bunches are incinerated and the ash from this process is used as fertiliser. Other empty bunches will go through a single stage presser to suck out the oil left in bunches. Then it sends to the field to be used as fertiliser.

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Figure 3.12 The fruit bunches been poured on the Auto feeder

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Figure 3.13 The thresher

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3.4.1.5 Digestion and Pressing The stripped fruits then are fed continuously into digester where they are converted into a homogeneous mash suitable for pressing. The digester are cylindrical vessels containing stirred on the way through. After digester the mash is transferred to double screw presses which extract the oil by pressure. The mash is subjected to increasing pressure as it is conveyed along the press by as crew. The press cages are perforated to allow oil pass through. Pressure at the end of the press is maintained by cone which maintains pressure automatically.

Figure 3.14 The Presser

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3.4.1.6 Derik caper After pressing the dried press cake, consisting of nuts and de oiled monocarp fibre and solids, passes to an air column which separates nuts from fibre. The fibre will sniff up to boiler station through fibre cyclone fan. The nut will move down into nuts polishing drum. The relation of air flow is:Q = VA where Q = density of air (ft/min) V = velocity of air (ft/min) A= area (ft3) If Q constant, V will increase

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3.4.1.7 Nut Polishing Nuts will transfer into nut polishing drum to clean nuts from fibre. In the same time this machine also has other function which to remove impurities like stone, wood, electrode and etc. Then nuts move out from drum through the hole at drum in size 3.5 cm to move down into nut elevator. There are 2 nuts polishing drum.

Figure 3.15 Nut polisher

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3.4.1.8 Nuts Drying After nuts polishing nuts transfer into nuts silo by nut elevator. Nuts will through drying process in nut silo with temperature 60°c - 80°c for 16 hours. Steam receiver from boiler is 30 psi. This process is to make nut cracker get crack nuts easily. During heating process the fan will sniff air to carry heat into nuts silo. There are have shaking grate to make nuts move down slowly and chute under nuts silo to flow nut into nuts cracker. Capacity of nuts silo is 27 tons. 3.4.1.9 Nut Cracking Nuts cracker is function to crack nuts to gets kernel. After this process appeared the kernel and shell in mixing condition. There are has a rotor in the nuts cracker which rotate in speed 1000 – 2000 rpm.

Figure 3.16 Nut Cracker

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3.4.1.10

Winnowing

Winnowing is a process to sniff up the light partial in Crack Mixture conveyer like small shell to shell bunker through Light Partial Fan (LPTS). The shell will as fuel for boiler. 3.4.1.11

Kernel/Shell Separation

This section is to separate kernel and shell. Kernel and shell which move in Crack Mixture conveyer will allow transfer into Hydro Cyclone. The Hydro Cyclone was divide 2 part which one for kernel side and one more for shell. Water was used as a medium in ¾ Hydro Cyclone. The water will bring kernel and shell in mixing condition into Cyclone by using pump. There is having Vortex, Spacer Ring and Discharge Cone in a Cyclone. Cone for kernel is size 80 mm and cone for shell is size 60 mm. Rotation of water with high speed will happed in cone for kernel and will cause kernel and shell will separate. Then kernel transfer into dripping drum kernel and shell transfer into shell side in Hydro Cyclone. Shell will pump into cone for shell side at 10 psi through a pipe. Rotation of water in high speed happened in cone side shell too with same principle. So there are 2 steps before get nice kernel. The kernel transfers into dripping drum one more time for last. The dripping drum is function for dripping process for kernel. Then kernel will flow down into vibrating screen through the chute.

Figure 3.17 Hydro Cyclone 47

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3.4.1.12

Kernel Drying

Wet kernel will flow down into bucket vibrating screen. Vibrating screen is function for dripping process by using vibrating system. The Vibrating system out of the centre method at the shaft. There are 2 vibrating screen. When bucket is vibrating the kernel will move down into Wet Kernel elevator. Then wet kernel elevator will carry the kernel into Kernel Silo for drying process by using bucket. In kernel silo kernel through drying process in temperature 50°c - 60°c for 16 hours. There are 3 kernel silos which each one have 2 heather and steam receiver from boiler is 30 psi. That steam will heat the heater and the kernel silo fan will sniff up into kernel silo dry the kernel. Capacity of kernel silo is 14 tons. Basic rule is same like nuts silo. Kernel drying process is important because to get the oil in kernel. Kernels also have the oil beside from the nuts. Beside that, this process also is avoid the bacteria appear from happened. The wet kernel condition will cause the free fatty acid will also increase quickly. The dry kernel will transfer into dry kernel conveyer after through kernel drying process. Next the conveyer will carry the dry kernel to dry kernel elevator to enter into kernel winnowing which will bring the dry kernel into the kernel bunker. 3.1.4.13

Kernel Bunker

The kernel bunker is last station which is use to storage the kernel. The kernel which was passes all process will stored here. Lastly that kernel transferred to other factory to process to make the product like cosmetic and many more. The kernel will transfer by using the lorry.

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3.4.1.14

Clarification

3.4.1.14.1

Vibrator

Oil from press will through Oil Gutter where is located under press to Oil Tank Press. Then oil will through three junction pipe to vibrator. The vibrator screen is function to remove impurities sand and sludge in oil. There are 2 type of filter of vibrator screen which is 20 meshes and 40 meshes. Next the oil will flow into Crude Oil Tank.

Figure 3.18 Vibrator

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3.4.1.14.2

Auto Decanter Crude Oil Tank

Oil from vibrating screen will flow into Crude Oil Tank. There are two columns in the Crude Oil Tank. Oil in first column will pump to Auto Decanter. The Auto Decanter is function to sink the sand and remove it. From Auto Decanter oil will flow into second column before pump to Distributer Tank. Capacity of Crude Oil Pump is 6 tons.

Figure 3.19 Auto Decanter

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3.4.1.14.3

Distributer Tank

Distributer tank is function to collect the oil from Crude Oil Tank at press Station. Then the oil will divide to Continuous Clarifier Tank and releases of oil pressure before send to continuous clarifier tank.

Figure 3.20 Distributer tank

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3.4.1.14.4

Continuous Clarifier Tank

Continuous clarifier tank is function to separate the oil and sludge depend the different of density. There are 3 columns in Continuous Clarifier tank which is separate with 3 plates in vertical position. Here separation process of oil and sludge happened. The layer of oil will appeared and the sludge is below the oil layer. The layer of oil is average in 10 cm. Capacity in Continuous Clarifier tank is 20 tons which temperature needed is 90°c - 98°c. The period for this process is 2 hours. The operator will collect the oil by using the skimmer that oil will transfer into the oil tank and the sludge will transfer into the sludge tank. The capacity both of tank is 10 tons for each one.

Figure 3.21 Continuous Clarification Tank

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3.4.1.15

Oil Purification

Oil in oil tank will transfer into oil purifier. The oil purifier is function to remove all dusty in oil by using centrifugal force in high speed. Temperature is needed in oil purifier is 90°c. Oil will flow from oil tank through inlet pipe to flow regular and next to distributer to move to disc set. In disc set separation of dusty and oil happened in rotation of disc. Then the dusty will flow out to discharge pipe and then the oil will move to float tank to go to vacuum dryer. Rotation in oil purifier is 1480 rpm for Alfa Laval type. Beside that from rotation will get heavy liquid 10 ka/dm3.

Figure 3.22 Oil Purifier

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3.4.1.16

Oil Dehydration

Oil from oil purifier will pumped to vacuum dryer to remove moisture in oil at 760 mm/hg where the water will remove at temperature 100°c. The capacity of vacuum dryer is 10 tons/hour. In vacuum dryer the oil will spittle through nozzle dryer which is of nozzle is 0.48 cm. Steam will sniff out by using the pump. When the steam change to water and will transfer to hot tank. The oil flow down to below area in vacuum dryer and flow out to transport pipe. The oil will pump transfer to bulk storage tank.

Figure 3.23 Oil Dehydrator 54

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3.4.1.17

Sludge centrifugation

Sludge separator is used to get oil in sludge because the oil still has sludge fluid and it using high speed with disc. Solid and water get separated to bowl hood and flow out by nozzle. The size of nozzle is 1.6 mm. Oil is more light of weight will flow by disc stack. Rotation in sludge separator is 1420 rpm. Beside that the sludge separator also uses auto flashing to clean the sludge separator. Cleaning process will spent 1 minute after run in 30 – 45 minutes. The oil from sludge separator will pump into reclaim tank and sludge into sludge trap.

Figure 3.24 Separator

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Reclaim Tank Reclaim tank is function to keep the sludge in short time and heat the mixing oil and sludge which flow from sludge separator and drained from oil tank. Then the oil from reclaim tank will pump back to continuous clarifier tank to recycle back through same process. Sludge Trap Sludge is use to trap back the sludge to get oil which free from sludge separator, and pre-cleaner. The oil will collected by using skimmer and transfer to reclaim tank. The sludge will allow flow to mixture raw effluent and through effluent treatment before allow to the river. 3.4.1.18

Effluent Treatment

Mixed raw effluent is a mixer of sludge trap and steriliser condensate. Mixed raw effluent will pump to aerator by power 15 KW and rotation of motor is 1440 rpm. At aerator is being cool process at this level. Sludge will pump from mixing pond to anaerobic digester. From here the sludge will arrest for 20 days. In this period will appear a few reactions. After all process for effluent treatment water will pass into the river. That water is safe to use daily. Quality of water out from this company is same with water in river and safe to use.

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3.4.1.19

Boiler

Boiler is heat machine which using to provide the steam for processing and generate electric power. Type of boiler is water tube. Water from steam feed pump will pass through check valve. The check valve is to allow water flow in one way only. Water will enter the steam drum at half level of steam drum. That water will be heated into partial steam-water. Partial steam-water will pass through superheat tube at header of boiler to get superheat steam and the superheat tube size is 1 inch. The superheat steam will pass through main stop valve to generate steam turbine. Main stop valve is function to allow the steam flow in one direction only.

Figure 3.25 Boiler

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Steam turbine is to generate alternator to supply electric power. The capacity of alternator is 500 KW and rotates at 4962 rpm. From alternator steam will transfer to reservoir to be use at other station like oil room, steriliser and press.

Figure 3.26 Steam Turbine

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Keeping the Boiler To avoid from corrosion happening a) Wet storage – water mixes the chemical and fills into boiler. The boiler needs to be checked every 2 or 3 month. b) Dry storage – this step taken when boiler not used for 6 month. The boiler need to be clean, dry and applied with hydrate lime or silica gel. There are 13 main components in a boiler Component Safety valve Main stop valve Gauge glass Check valve Fusible plug Water alarm Fuel cut off Pressure gauge Test gauge connection Feed pump Blow down Register plate Manufacturing plate

Function To release over pressure in boiler by blow out off the steam and avoid the boiler from explode Allow the steam to flow out only Show the level of water in boiler Allow the water to enter into boiler only For safety Show water level in drum To cut off the fuel Show the steam pressure Testing the steam pressure Pump the water into boiler To reduce water quantities in boiler The number which was registered Supplier Table 3.1

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Overhaul Boiler 1. Release steam in boiler until empty. Let it cool on it self. 2. Provide blank at the suitable place. a. Main stop valve b. Channel for steam feed pump c. Channel to fill water d. Channel to remove water 3. Provide the tool such as chipping hammer, transformer, hand lamp, dust respirator, goggle, the wood to make platform in boiler and more. 4. Safety first 5. Doing outside work like chimney I.D fan, open mud box, cover header, make platform in furnace and clean all tube in furnace. 6. Open airlock when pressure reduced to 0 psi. 7. When boiler really cool remove water through blow pipe and drain header. 8. Open the gauge glass and put the caps and gauge glass carefully. 9. Open plate in steam drum and water drum by using cleaner tube with pressure air metre electric pump. 10. Replace the stone which was damaged. 11. Mark on tube which was damage.

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12. Make sure the part which not cleaned yet. 13. Provide the tool for inspection by engineer.

3.4.2

Scheduled Maintenance for Shoot Blower of Boiler Shoot blower is a device a fitted to the boiler to keep it at optimum performance. The

shoot blower main purpose is to clean the ashes from the steam pipe in the boiler. It functions by shooting high velocity steam through tiny holes along the pipe. This pipe can be rotated 90 degree only. The holes are perfectly made in the pipe according to the arrangement of the steam pipe in the boiler. During the boiler operation, the fire is blown between the steam pipes. At that time the ash also fly that way. As times passes by the ashes start to collected between the steam pipes it self. If the ashes did not been remove it will start to solidify. When that happen the water can not be heathen effectually because most of the heat are absorb by the solidify ashes. This shoot blower pipe inject high velocity steam to the solidify ashes. The steam will shatter the solid ashes into tiny pieces. Then it blew away by the steam. Some of the ashes get stuck into the tiny holes in shoot blower. Firstly the boiler has to be shut down. It let to be cooled over night. Then the shoot blower pipe is pull out of the boiler. Using chipping hammer solid ashes that grabbed on to the pipe surface are cleaned away. Then high velocity air is blown into the pipe to clean the tiny holes. All the remaining ashes are washed away with water. New heat proof paint is painted

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on to the shoot blower pipe. Then the shoot blower pipe is fitted back to the boiler and connected to the incoming steam pipe.

Figure 3.27 Shoot Blower

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3.4.3

Scheduled Maintenance for Overhead Crane The overhead crane is the main important machine in this oil palm factory. It

responsible to transfer the sterilized fruit bunches into the fruit thresher. The wheel and the cable of the crane need to withstand more than 3 tons in hot condition. Firstly the overhead crane is shut down from operation. The hook is lowered to the floor to reduce the total weight. Then a chain block is attached to the on wheel of the overhead crane. The wheel is lifted of the rail. Then the bolts that hold that wheel are taken off. The wheel then taken off the main body. The wheel brings to the hydraulic machine. Using hydraulic machine the old bearing push off the wheel. The wheel then disassembles from the holding bar. A new wheel with fitted new bearing assembled to the holding bars. After that the wheel fitted back to the crane. The bolts are tightening. The wheel then lowered back to the wheel. The same procedures are applied to all other 3 wheels. After all wheels have changed, the wheels are aligned properly to the rail to avoid any accident. The gearing part is applied with greasing for smooth operation. One end of the cable is loosened. Then the rest of the cable is pulled off the hook pulley by hand. Then the other end of the cable also loosens off. A new cable which measured 49.5 m (length) X 11 mm (diameter) is fitted to the drum. The other end is fitted through hook pulley and back to the drum. The clippers that hold the cable to the drum are tightening. Finally a lot of grease is applied along the cable and the drum.

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3.4.4

Changing the Steam Turbine Alternator This company produce its own electricity power. The electricity power not only use

for the factory but also supplied to the estate houses of this company. They have 2 huge steam turbine alternator that been use since electric been use in this factory. They even have 4 alternator powered by diesel engine. They cut the production cost for electricity because they have their own turbine. Before electricity been use, this factory use massive belt drive system to operate the entire machine. At that moment the biggest problem was, when a belt is broken off then the entire factory has to be shut down to repair it. At time production was at slow past. When the electric motor introduced the belt system immediately changed to it. Then the production rate get boost by electricity. The number 2 steam turbine alternator was reported to be producing weird sound during operation. One of the alternator bearing is wearing off. So the bearing has to be changed. Firstly the steam supply to the turbine is cut off. It has to be done to dismantle the alternator. Then all the output electric cables are loosening off. The boxes that bring the cable also need to be removed. Then an A frame is assembled directly on top of the alternator. The coupling that joints the turbine and alternator dismantled on by one. The bolts that hold the alternator to the base are loosed. Using two chain blocks the alternator lift off the base and carefully lowered to the floor. A few pipes placed below the alternator that acts like rollers. The alternator is carefully dragged out the engine room and sends out to be repaired. 64

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A few days later the alternator has repaired. The same technique use to drag the alternator back into the engine room. Then the alternator lifted of the floor and placed on the base according the original coordination. All the cables, bolts and coupling fitted in. The steam turbine is now running like new.

3.4.5

Overhauled Purifier There was a report that saying purifier number 2 is no working very well and it

transmission oil is leaking. Firstly the purifier is shut down and let to cool down for few hours. After that the inlet and outlet are taken off. The clamping shoes are loosening to open the top cover and collecting cover. The flow regulator also loosens. When the cover is opened is will uncovered the frame top part. Then the lock rings are unlocked. The packing, gravity disc diameter 90, seal ring and bowl hood are separated from the machine. The whole distributer, bowl disc and top disc are taken out completely. The cap nut and screws are loosed. The distributer cone, lining and sliding bowl complete are taken off the machine. The screws that hold the bowl body are loosed and the bowl body dismantled. Then the horizontal part also dismantled to pieces. During that time the transmission oil is drained through the drain nut. The bowl spindle is dismantled as well. Then all the frame parts are taken off including hinge bolt, pawl and buffer, hood for paring disc device, sludge discharge bend, vibration damper, bottom bushing, brake and motor bracket. All the gearing system at the bottom of frame also dismantled. All the parts including the frame are washed and dried. All the oil seals, bearings, o rings, packing are changed with new one. Then the purifier is assembled together the same 65

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way that it been disassembled. After assembled about 10 litres of new transmission oil is purred in. Then it let to run for few minutes then it ready for it purification process. 3.4.6

Overhauled Ripper Mill or Nut Cracker Firstly the ripper mill is brought to the work shop. Then the ripper mill is dismantled

into pieces. After that the bottom case of the ripper mill that holds the nut cracking rods is grinded. All the nut cracking rods are taken off because it has worn off. At the inlet of the bottom case the wall also worn off. At that section filler weld done to get it thicker than before. After weld that section is grinded to get smother surface. Then new set rod measuring 17 inches long and 1 inch diameter inserted into the place of the bottom case. The drum also dismantled and a new set of rod inserted measuring 15 inches long and 1 inch diameter. The rods are placed forth and backward in the drum. Then the walls that containing bearing and adjustment screw are fitted to the drum. After that the bottom case is fitted between the two walls. Finally the top case fitted together. All the bolts are tightening. The adjusting screws are adjusted until the gap between the drum rods and the bottom case rod are just about half inches. Then the ripper mill is mounted to the bottom of the silo. The motor is fitted. Advantage •

Get to know the process involve in extracting the palm oil

•

Able to learn about the boiler

Disadvantage •

Not enough time

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•

Less guidance

Suggestion • 3.5

Need more guidance VECHILE MECHANICS

Objective of training in this section •

Learn about the petrol engine

•

Learn about the diesel engine

•

Learn about the tractors

•

Learn about the heavy machinery Other than the locomotive this company also uses vehicle like tractors and heavy

machinery to maintain the field and factory. In side the factory especially on the marshal field they use two Cater Pillar 910 to push and pull the fruit cages. In the field they use Massey Ferguson tractors and John Deere. The size varies from small to big. The engine capacity starts from 3 cylinders to 6 cylinders. Every tractors and heavy machinery are service monthly keep it at optimum performance. Before the use of tractors and other heavy machine, this company was using traditional transportation like bull wagon. After the introduction of the heavy machinery the productive of this company increase by several times.

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3.5.1

Ipto Clutch Overhauled This ipto clutch serve as a drive shaft for the machine that tow behind the tractor like

grass cutter and trench digger. Firstly the tractor is parked under roof. Then the tractor lifted and placed on the supporter for further operation. The transmission oil drained out the transmission box. Then the bolts than hold the body together are loosed. Carefully the body is separated into two sections at the transmission box. The ipto clutch is taken out of the transmission box. The clutch is dismantled into pieces. When examined all the plates and the discs are worn out. A new set of the discs and plates are ordered to replace. The discs and plates are arranged in alternate and placed in the housing. It then secured with snapring. After that the ipto clutch attached back to the secondary transmission in the transmission box. After that the tractor is joined together and filled with transmission oil. A few test run done to test the new clutch disc.

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Figure 3.28 Ipto Clutch parts

Figure 3.29 Two section tractor

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3.5.2

Rear Axle Housing Overhauled Firstly the tractor is jacked up. Then the rear wheel is taken up. The transmission oil in

the rear axle housing is drained through the drain plug. After that the nuts unf and bolts unf are loosed. The cover is slowly taken off and the parts are dismantled. All seals and the bearing replaced with new units. The parts are cleaned in the diesel oil and dried. Then it put together one by one. Some grease is applied inside the pinion and the needle stack inside. The grease will hold the needle together like glue. All three pinions done in the same way. After that the pinion pads with the washers and slowly slides into the carrier. The clevis pin inserted and locked with pin. Then the shaft inserted into cover and locked with circlip. The carrier slide on to the shaft. Then the annular gear fitted on to the cover. Finally the rear axle housing is fitted back to place. The rear wheel fitted and the gear oil filled up again.

Figure 3.30 Rear axle Housing

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3.5.3

Engine Overhauled Firstly the engine block is cleaned up with the diesel. A thin film of engine oil apply

on the inside surface. The pistons are fitted with the oil rings and piston rings. Then it fitted to the piston rod. A thin film of oil is applied to the pistons. After that it fitted to the crank shaft through the piston cylinders.

Figure 3.31 Piston Then all the piston rods bolts tighten with torck wrench about 70 lbs/ft. After that the fly wheel mounted to the crank shaft. The engine oil pump is mounted at the bottom side of the engine. After that the aluminium cover which contains the water pump is mounted. Then the gears fitted according the mark on it. If the gears not fitted correctly it will result some

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damage to the engine and may the engine will not start at all. Then the fuel pump is fitted on the gear. The bolts that hold the fuel pump are tightening.

Figure 3.32 After the gears aligned the front black cover is fitted. The vacuum pump fitted on top it. Then the oil reservoir is fitted to the bottom of the engine. After that a temporally engine mounting is made. This is made to avoid the engine from placed on the oil reservoir and damage it. The temporally engine need to be strong and stable because the test run will be done before mounting it inside the body.

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Figure 3.33 Then the engine head is fitted on top of the engine. The engine head hold the valve and etc. The rocker arm then fitted to the engine head. On top of the rocker arm the cam shaft installed. Then the cam shaft pulley installed. After that the timing belt fitted and the timing of the engine is checked. After that the valve clearance adjusted according to firing order. The firing order of this engine is 1 – 3 – 4 – 2. The valve clearance is set at 0.13 mm for inlet an outlet. Then the cover is fitted. After that the nozzle is fitted with the fuel pipe from the fuel pump. The air intake manifold and exhaust manifold are fitted in place. After that the radiator fan, alternator and starter are fitted to the engine. The engine oil and engine coolant filled in. Then a temporally fuel line is fitted. Then the engine started for the first time. A few adjustments done until the engine start. The engine let to run at low rev for few days.

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Figure 3.34 After satisfy with the running condition all the temporally parts taken of including the radiator, fan and starter. Then the engine lifted of and lowered into the pickup. The engine mounted on the engine mounting. The battery, fuel line, starter, fan, air conditioner compressor, radiator and wires are fitted properly. The engine started and done some test run.

Figure 3.35 74

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Advantage •

Lean more about the engine

•

Able to overhaul the engine

•

Get experienced instructor

Disadvantage •

Very limited time

Suggestion •

Increase the training period

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4.0 CONCLUSION AND RECOMMENDATION 4.1

Conclusion As long as 20 weeks at United Plantations Berhad Ulu Bernam Engineering

Department, I get a lot of knowledge, skill and experience about manufacturing of palm oil mill and maintenance of the machine involve with the process. From processing the oil palm to maintenance works in this company. In this period I give a lot of my energy to this company especially in maintenance activity but I get much knowledge and experience in what I did. Here I did the welding process, cutting using oxyacetylene, overhaul gear box, overhaul engine, repairing, solve the problem in maintenance activity and many more. That means all jobs for workshop need to be done. Actually the job for maintenance is very important because if any breakdown happened during process and it is workshop responsibility to settle it. So the members of the workshop department need to take this responsibility to solve the problem. If not, this company can to get to process the oil palm. Workshop need to repair or solve any problem to make sure this company will runs in 100%. By this way, this company will able to continue back to process. It also can increase the productivity of the company. Beside that we work under engineer department need to make sure that all maintenance in all section done well. So the engineering department need to preventive maintenance to avoid the machine breakdown. It also can reduce cost budget for this company to repair the problem. Avoid problem is good step than repairing.

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This is our responsibility when work under engineering department. All members of engineering department need to take this responsibility including my self. We need to take care of our company. Actually our job is to improve the productivity of this company and improve the product of output from the company. As a conclusion the experience during industrial training for 20 weeks under engineering department expose me to the actual working environment, improve my knowledge and skill which can guide me when I join the workforce upon completion my study in UTeM. Besides learning something which relate to the subject I learn, I also been given an opportunity to learn about the product, work as a team workers, communicate with the engineers and supervisors in engineering department. Working experiences a professional is a good experience obtained while industrial training at United Plantations Berhad Ulu Bernam Engineering Department. I learn how to apply the tool and technique that I have learnt before. 4.2

Recommendation In engineering field, the maintenance only is not good. To become and engineer need

to solve the problem and improve it to get improve the productivity. In industrial training activity for 20 weeks I saw a few problems which need to solve and need to improve here. Here I hope will get improve productivity for this company. There are a few of problems stated below:Problem 1.

The kernel falls down on the road during transfer operation into the lorry under kernel

bunker. These problems will reduce the productivity product because that kernel is high quality. So this problem will be lost to company. 77

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Solution 1.

Need to check the source the problem whether it from the kernel bunkers or mistake

from operator during transferring. Problem 2.

The kernel also moves out during transferring into dry kernel elevator. It cause the

kernel fall of on the floor. Solution 1.

Make the cover around the chute to avoid the kernel move out around the dry kernel

elevator. 2.

Can use the zinc, aluminium or galvanize plate to do the cover.

3.

Can do rivet joining on the chute because the chute already made from hard material.

Problem 3.

The kernel in bucket vibrating screen always flow out while it running. The kernel

flow out because using vibrating system. Solution 1.

Modified at bucket to more big and make sure the wall high enough to stop the kernel

fall from the bucket. 2.

Second method is just adding the nets at body of bucket by using the bolt and nut

because that body made from hard material.

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5.0 REFERENCE 1)

A Century of Progress..... 1906 – 2006 United Plantations Berhad 100 Year Anniversary, 2006.

2)

Annual Report 2006 United Plantations Berhad, 2006

3)

Massey Ferguson 399 Owner Manual Guide Book.

4)

Massey Ferguson 375 Owner Manual Guide Book.

5)

Alfa Part Sheet.

6)

www.unitedplantations.com

7)

Periannan, Workshop Supervisor, Ulu Bernam Engineering Department, United Plantation Berhad.

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6.0 APPENDICES

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