Siti Mardiah completed a 3-month internship from April to July 2015 as an assistant engineer in the process department of Lafarge Pasir Gudang Plant. During her internship, she gained exposure to technical processes like mill and weigh out inspections. She also worked on projects to optimize the plant's shutdown sequence, reduce idling equipment in the silos, and analyze grinding aid and gypsum trials. In addition, she learned non-technical skills like developing professional relationships and improving her attention to detail. Overall, the internship helped her apply her knowledge practically and identify strengths and weaknesses to develop further.

1. Internship Presentation
Siti Mardiah binti Johani
1st
April – 1st
July 2015
Asst. Engineer – Process Dept

2. Content
1. Objective of Industrial Training
2. What I’ve been exposed to
3. What I’ve learned
Conclusion
Date | 2

3. 1. Objective
 Get exposure on professional working environment
 Gain beneficial industrial experience
 Applying theoretical knowledge on practical job
 Get a taste on how working life would be
 Discover self potential and weakness
Date | 3

4. 2. What I’ve been exposed to
Date | 4
In Lafarge Pasir
Gudang Plant
Technical
Knowledge
Non-Technical
Knowledge

5. 2.1 Technical Knowledge
2.1.1 Assisting on inspection job
Date | 5
 Mill inspection
1. Calculation on volume loading done according to Vade Mecum’s guide book
2. Observation on liners, ball coating, intermediate diaphragm and protocols on
entering a confined space ( LOTOTO )
 Weigh Out
1. Objective to verify % error between reading on site and DCS reading
2. Had the chance to lead on weigh out according to Production’s request

6. a. Sequencing equipment during start up and shut down
Objective
1. To change the current way of shutting down the plant via centralized system and
turn it into a sequenced stoppage
2. Save power as a more efficient shut down can help reduce power wastage
3. Planning a sequence that can prevent mill from trip
Method Used
1. Observation on methods used by CRO during PM
2. Listing out problems that rise during shutdown and try to provide ample time and
sequence for the equipments.
3. Do calculation on time and cost saved based on estimation timing given by CRO
Date | 6
2.1 Technical Knowledge
2.1.2 From projects assigned

7. 2.1 Technical Knowledge
Proposed solution
Date | 7
Group Current situation Change
4_5
Clinker and
GypsumFeeding
Needed to Off and re ON then reoff due to
interlock that trips mill if there is no feeding for
more than 10 minutes
For PM, prevent mill from trip when
there is no feeding for more than 10
minutes. Set time for 20 minutes at
least, to empty out mill
4_4
Mill Main Drive
NC NC
4_3
Cement Auxilliary
NC NC
4_2
Separator and
circulation
- Normally CRO adjust the fan opening
2.27 to, decrease the opening gradually
from the moment they off group 4_5
- After stoppage of purging 2.26 bag filter,
there is a rise of power in BE 2.20 up to
30 KW. CRO have to stop feeding into
the bucket to prevent trip
- Set in program to have cascade
decrease in opening of fan 2.27
from current to 0% within 20
minutes
- Set all 2.26 screw conveyer and
rotary valve in 4_2 to stop when
the purging stops. Also it has to be
re ON after an estimated time of 1
minutes to clear out the materials
inside the SC&RV
4_1
Transport to Cement
silo
- CRO switch ON and OFF the screw
conveyer and rotary valve in an
unsystematic way . Large amount of
materials lies inside screw conveyer.
- Switch ON screw conveyer and its
couple one by one for 2 minutes
then OFF
2.1.2 From projects assigned

8. Date | 8
2.1 Technical Knowledge
2.1.2 From projects assigned
 Conclusion
With an estimated number of 2 PM/mnth, savings up to RM 433.50/yr
 Work left to be done
 Test out proposed timing sequence for shutdown and start up
 Study on programming interlocks

9. 2.1 Technical Knowledge
b. Idling equipment on silo B
Objective
1. Eliminate idling equipment
2. To save power from idling equipment during tanker loading
Method
1. Study automated system in silos, where improvement can be made. Potential for
improvement was identified in silo B.
2. Identify equipment used during tanker loading in silo B.
3. Learn how the system works when there is tanker loading cement.
4. Plan how to eliminate the idling equipment
 Proposed solution
When lorry driver pushes the pendant switch to lower down the bellow, it
automatically activates the equipments in silo B. When he pushes the pendant switch
to bring up the bellow, it deactivates the whole system.
Date | 9
2.1.2 From projects assigned

10. Date | 10
Calculation done with consideration of these parameters :
Parameters Remark
1 Frequency of tanker coming in on each loading point Data collected from supply chain
2 Tanker waiting behind the current loading tanker
Taken into consideration through the
percentage of manual action taken
3 Rise in motor consumption during each start up Only for a few seconds thus negligible
4 The percentage of motor capacity used when running Only 80% motor capacity used
5 Operator shutting the system when not in used Assume 50% from total time saved
6 Simultaneous pumping 30% number of lorries
2.1 Technical Knowledge
2.1.2 From projects assigned

11. 2.1 Technical Knowledge
Conclusion
Saving up to RM 12 308.25/yr and with an estimated cost of RM5 000, expected
payback will be in 0.41 yr.
Work left to be done
Co-operation from E&I department to plan the programming and provide electrical wiring
on silo B
2.1.2 From Misson assigned
Date | 11

12. c. PID on weigh feeder
Objective
1. Stabilize and optimize weigh feeder output ( TPH)
Method handling PID
1. PID tuning involves access to the equipment during manual and automatic mode.
We had to identify what are the parameter that we want to tune and what
disturbances could give major impact on that particular parameter
2. Tuning on : Clinker feed (TPH)
Disturbance: Speed of belt conveyer
3. Tuning during manual mode could give us data on the dynamic of the process.
We can have information on how fast does the process react to disturbances.
4. The most common method to tune in manual mode is through echelon method.
About 10% rise in speed of belt conveyer is applied on the weigh feeder.
Date | 12
2.1 Technical Knowledge
2.1.2 From projects assigned

13. 6. After calculation, we have to enter it inside the weigh feeder system and let it run
in auto mode. Observation on how the process reacts is needed for tuning. Tuning
involves user adapting to the process and change the value accordingly
 Conclusion
I was unable to complete the project due to limitation on this plant. When the weigh
feeder is in manual mode, we are unable to get access to its feed reading.
Thus, if disturbances are made, we won’t get the data on how the process had
reacted.
Proposed solution : Try and Error tuning in auto
Date | 13
2.1 Technical Knowledge
2.1.2 From projects assigned

14. d. Analyse on Grinding Aid Trial
 Objective
1. To find a grinding aid that gives the best results in terms of quality, process and
cost.
 Method
1. Analyse the data
2. Several discussions had been made to verify the analysis done on the results. In
order to choose the best GA, rating is given to GA with best performance to low
performance
3. Before making a final decision, a meeting with production, quality and process
team along with the plant manager had been held to further discuss on the
findings
 Conclusion
Based on analysis done, GA (Grinding Aid) Mapei had shown the best performance and
is recommended to be used in PGP
Date | 14
2.1 Technical Knowledge
2.1.2 From projects assigned

15. e. Analyse on Gypsum and Anhydride Addition
 Objective
1. Find the right ratio for gypsum and anhydride addition that can give best result in
IST (initial setting time )
2. Other monitored parameters :
Date | 15
2.1 Technical Knowledge
2.1.2 From project assigned
So3
percentage
Within 2.8 to 3% ( set by quality team)
SA 3500 to 3700 cm2/g
Gypsum If possible , low % because running out of natural
supply
Strength
2d strength
28d strength
High strength
Average strength 2 days : 28.50
Average strength 28 days : 53.00
Pattern Consistency in results gained through experience

16.  Method
1. Work on raw data
2. Analyse data according to parameters set earlier
 Results
Date | 16
2.1 Technical Knowledge
2.1.2 From project assigned

17. Discussion
Date | 17
2.1 Technical Knowledge
2.1.2 From project assigned
% of Gypsum 0 25 50 75 100
Initial setting time
(min)
113
1 minute
later than
75% of
gypsum
125
13 minutes
late than 75%
gypsum
125
13 minutes
late than 75%
gypsum
112
Lowest IST
113
1 minute later
than 75% of
gypsum
SA
(350-370 m2/kg )
379.6
2.5%
higher
than target
355.6
In range
365.8
In range
374.2
1% higher
than targeted
370
364.4
In range
SO3
(2.8-3%)
3.28
9% higher
than target
2.73
2.5% lower
than target
3.25
8% higher
than target
3.23
7% higher
than target 3
2.21
21% lower than
target
2 days strength 31.64 23.59 30.57 32.76 26.83
28 days strength 55.06 50 53.31 54.32 52.01
Consistency in
results
3/4 results
between
range
110<IST<1
30
1/4 results
between
range
110<IST<130
1/4 results
between
range
110<IST<130
4/4 results
between
range
110<IST<130
2/4 results
between range
110<IST<130

18. Cost
Saving up to RM 22 899.28 /yr when using 75% gypsum
Conclusion
More pros can be seen on the results gained from 75% of gypsum + 25% on
anhydride than the other compositions in terms of IST, 2d strength, results
consistency and costs.
Date | 18
2.1 Technical Knowledge
2.1.2 From projects assigned

19. H&S Blitz Program
I was able to participate in many trainings :
1. WAH Training : Definition of WAH, at-risk behaviour, fall protection system and ways to calculate our fall was
explained
2. Tools and Equipment : Explanation on hand powered tools, non-powered tools, how inspection must be done
regularly, and measures needed to be taken to prevent unwanted incidents
3. Hot Work: Explanation on type of welding (welding arch, welding iron rod, welding torch), combination of oxygen
and acetylene could give out big and sharp fire, Pre Job before welding and permit needed to do welding.
4. Energy isolation : Explanation on types of energy, importance of energy isolation, basic requirement to do energy
isolation, existence of working procedure such as HECP and HERA, LOTOTO
5. Hazardous substances: Chemical substances that are present this plant that gives threat to our health. Example
such as cement, raw materials and chemicals used for lab testing
 Fire Fighting training in Bomba Pasir Gudang
 DOM meetings
 RCA ( Root Cause Analysis)
Date | 19
2.1 Technical Knowledge
2.1.3 From Training and Activities Joined

20. Date | 20
2.2 Non-Technical Knowledge
1. Human relation
As the plant has a small number of employees. I had the chance to know and work with
almost all of them. People here are very nice, welcoming and helpful. There is a
positive working environment here which makes people feel good about coming to
work. I can see that most people have a balance between work and personal life.
2. Quality of work and Managing time
Based on comments on my work, I still need to improve the quality of my
work. As I am not really a meticulous person, I will try to improve myself on looking
more closely into tiny details.
2. Autonomous
Assignments given to me are closely linked with electrical and instruments which is
not my strongest field of study. I had to be guided closely by Mr. Badrul as he had to
explain to me how the system in PGP works. I need to improve myself on this
particular field as being a process engineer also requires me to be at ease with E&I.

21. 4. Leadership
On issues raised, a leader must quickly identify the problem, see how it can be solved
or set a discussion about it and must be able to make a quick and smart decision. To
be a good leader is not easy as they have to be aware of every single thing, both
technical and management side. They have to be encouraging and appreciative of
people’s work.
Date | 21
2.2 Non-Technical Knowledge

22. 1. Assignments given to me helps me to understand better operations
in the plant and on cement industry
2. I am able to identify my weakness and will work on improving myself.
But, far yet to discover my potential
Date | 22
3. What I’ve learned

23.  Get exposure on professional working environment
 Gain beneficial industrial experience
 Applying theoretical knowledge on practical job
 Get a taste on how working life would be
 Discover self potential
 Discover weakness
Date | 23
Conclusion

24. Date | 24
Thank You