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  • 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
  • 9.
  • 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
  • 14.
  • 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.
  • 17.
  • 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
  • 23.
    • Smart field communicator
    • 24. Hand pump
    • 25. Panel for breaker test
    • Simulator circuit breaker
    • 26. Thermal overload test
    • 27. Tool box
    • Non flammable contact cleaner
    • 28. switching protection clothes
    • 29. Infrared cam
  • ELECTRICAL INSTALLATION
    Our main consideration of installation electrical equipment is ‘safety issue’
    Ex: Current leakage, Overflow
  • 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