BP Chemicals (M) Sdn. Bhd hosts industrial trainees to expose them to the chemical production industry. The trainee spent 6 months learning about BPCM's Purified Terephthalic Acid production process, maintenance practices, and health and safety standards. The trainee gained hands-on experience servicing electrical equipment like motors, breakers, and generators. They also learned instrumentation skills including transmitter calibration and installed new equipment. The extensive training program helped prepare the trainee for a future career as an electrical and instrumentation technician in chemical production.

1. BP CHEMICALS (M) SDN. BHD12 JAN – 12 JUN INDUSTRIAL TRAININGPOLYTECHNIC 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 practiceTo introduce students to work culture and industrial practicesTo give opportunity to students to work with industrial practitionersTo expose students to potential employersTo acquaint the Polytechnic students with industry and its programsImplement Health Safety and Environment (HSE) practices at workplace.Practical ethical professional work culture.Acquire skills in communication, management and team-work.

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

5. Overview of BPCM

6. Overview of BPCMLocated 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 resinsIt 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. BPCMPRODUCTAn aromatic acidPhysically - White - Crystalline powder - Looks like powdered sugarRaw 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 MIXINGCRUDE TATO STORAGECRYSTALLIZATIONPrecipitation from SolventOXIDATION REACTION SOLVENT PARAXYLENE CATALYSTAIRSTEAM TUBE DRYERRemove moistureFILTRATIONSeparation TA Solids & HAc

12. Overview of BPCM-PTA Process (Purification) FEED SLURRYPURIFIED TATO STORAGEHYDROGENATIONREACTIONCRUDE TAPROCESSWATERCENTRIFUGING & FILTRATIONRemove p-ToluicsHYDROGENSTEAM TUBE DRYERRemove moistureCRYSTALLIZATIONPrecipitation from SolventCrude TAProcess Water

13. MAINTENANCEORGANIZATION

15. POWER DISTRIBUTION OF BPCMStep down ration from 132kV to 11kV132kV 11 kV

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

18. EXPERIENCES ELECTRICALSServicing motor and breakerDo 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 storageInstall electrical equipment. Ex: socket, grounding for dischargeGreasing motorTest run generatorElectrical safety in hazardous areaElectrical isolation

19. Instrument Do installation/calibration of pressure transmitterMetler Toledo Training- new sensorCalibration of pressure switch

20. Electrical toolsCable detectorPower qualityMulti meterAvo meter

21. Tripping toolsClamp meterCathodic protection tools

22. Insulation testerPipe bending

23. Smart field communicator

24. Hand pump

25. Panel for breaker testSimulator circuit breaker

26. Thermal overload test

27. Tool box Non flammable contact cleaner

28. switching protection clothes

29. Infrared camELECTRICAL INSTALLATIONOur main consideration of installation electrical equipment is ‘safety issue’ Ex: Current leakage, Overflow

30. Trainee ActivitiesService Breaker and Motor

31. Working at panel motor control center

32. 415V Circuit breaker and motorcontactCurrent transformerThermal overloadStart &stop indication lightCircuit breakerReset 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 serviceCheck all connection and cable sleevePhase inlet & outlet stab connectorsNeutral inlet outlet stab connectorsAux contactEarth contactContactor terminalsTimer terminalFuse terminalsCurrent transducer terminalsTerminals outgoing (compartment)Check abnormality patended supportsService contactorLubricant moving mechanismFunction test rack in test pos. limit switch

39. Function test remote off selector switchFunction test overload relay500V megger at close position RE,YE,BE,RN,YN,BN, RY,RB,YBResistance check at open and close position

40. 6.6kV breaker

41. Breaker part repairing

42. 11kV Breaker operatingRepair in progress

43. Example motor

44. INDUCTION MOTOR

45. ROTOR & WINDING

46. MOTOR WINDINGS TESTMotor windings resistance checkMotor windings insulation test with earth 415v(500V), 6.6kV(1kV)Lubrication see rating plateClean motor head exchange cooling fan

47. Generator test runProcedure to start

48. 3mW generator procedureCheck air compressorCheck generator and engine roomCheck battery panelCheck master control panel at substationCheck generator control panelCheck & record meter readingStart more than one hourStop generator

49. Overview of generator

50. troubleshootWiring installationBreaker failure cannot energized. Vacuum cleaner ,one motor carbon brush failure Plug direct on line starter

51. Repair Welding setVacuumWring installationPlug 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 storageCathodic 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 partReplace compressor ac 132kV substation

60. Instrument partCalibrateInstalltraining

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