Jabatan Kerjuruteraan Mekanikal Politeknik Ungku Omar Ipoh, Perak Darul Ridzuan

POLITEKNIK UNGKU OMAR| 1
JABATAN KERJURUTERAAN MEKANIKAL

POLITEKNIK UNGKU OMAR
IPOH, PERAK DARUL RIDZUAN
LAPORAN LATIHAN INDUSTRI

SESI JUN 2014
MUHAMMAD HIDAYATURRAHMAN B RAHMAT

01 DKM12 F2043
DIPLOMA KEJURUTERAAN MEKANIKAL
PETRONAS PENAPISAN (M) SDN BHD

SUNGAI UDANG
MELAKA
DEDICATION
This report was dedicated to my parents who have supported me all the way since
the beginning of my studies till now.
Also, this report was dedicated to my siblings and not forgotten also my friends who
has been my great source of motivation and inspiration. Finally this report was
dedicated for all those who believe in the richness of learning.
STUDENT ADMISSION
I recognize this work is my own work except for excerpts and summaries of each of
them I have already explained the source.
Signature :
Name : MUHAMMAD HIDAYATURRAHMAN B RAHMAT
Registration No. : 01DKM12 F2043
Course : DIPLOMA OF MECHANICAL ENGINEERING
APPRECIATION
Praise to Allah for his blessings, I have finished this report as it is a
requirement for me to get the Diploma of Mechanical Engineering. A handful of
thanks I bid to Mr Wan Abd Rahman, my task evaluator and the staff of Petronas
Penapisan Melaka Sdn Bhd who helped me a lot by giving me useful information
and for pointing out my mistake so that my work will give out an excellent result.
Special thanks I bid to Mej. (K) Dato Hj Md. Nor Bin Yusof, the director of
Polytechnic Ungku Omar, for without him allowing the industrial training to be held,
there will be no field of experience for us. Also for academic advisor, coordinator of
the industrial training and lecturers who made this all possible for us by teaching
from the basic of mechanical engineering to the advance knowledge of the subject. I
am thankful for that because without any knowledge given to us earlier, we will not
be able to do anything due to lack of information about how engineering works.
I am nothing without my parents. Therefore, I would like to thank them for
giving me support that I needed to finish this course especially when it comes to
moral and financial support. Many thanks I bid also to my fellow friends for giving
me the spirit and showing me some things that I do not know during the period of
industrial training.
As a conclusion, this report will not finish successfully if I had not receive
help from other person above. I will be forever in debt for their good deeds that they
have done for me.
ABSTRACT
Industrial training is one of the necessary thing that need to be carried out by
the students in polytechnic. The polytechnic has fixed a period of one semester for
each student that have passed the prequisitory condition. Industrial training time span
starts from 23th June 2014 till 7th November 2014. This industrial training were
carried out to expose students to the real working experience on their respective
fields. Apart from that, this training aim for students to practice about what they have
learned during their earlier semester in polytechnic and they will improve their skill
in the field that they are involved in. The log book on the other hand is an overall
record during the industrial training. The log book contain industrial training
information of the organization, technical report, to record works carried out during
their training period and their summary, also contain comments and suggestion for
organization for future improvement. Overall, this log book will be presented to the
polytechnic to be evaluated and it will be used by polytechnic to understand more
about the work done by the students during the period of the training.
ABSTRAK
Latihan industri merupakan salah satu perkara wajib yang perlu dilaksanakan
oleh penuntut di politeknik. Pihak politeknik telah menetapkan jangka masa selama
satu semester bagi setiap pelajar yang melepasi syarat-syarat tertentu. Tempoh
latihan industri bermula dari 23 Jun 2014 hingga 7 November 2014. Latihan industri
ini diwujudkan bagi mendedahkan para pelajar terhadap bidang masing-masing
dalam dunia pekerjaan sebenar. Selain itu, latihan ini bertujuan untuk para pelajar
mempraktikkan apa yang dipelajari di politeknik sekaligus dapat meningkatkan ilmu
kemahiran dalam bidang yang diceburi. Buku laporan pula merupakan satu catatan
keseluruhan sepanjang pelajar menjalankan latihan industri . buku laporan ini
mengandungi maklumat latihan industri bermula dari maklumat organisasi, laporan
teknikal, catatan kerja-kerja yang dilakukan sepanjang tempoh yang diberi serta
rumusan, komen dan cadangan untuk organisasi bagi proses penambahbaikan pada
masa akan datang. Secara keseluruhannnya, buku laporan ini dipersembahkan untuk
pihak politeknik menilai dan memahami setiap kerja yang telah dilakukan oleh
pelajar semasa menjalani latihan.
Table of Content
Content
Page
Front Page
Dedication
Student Admission
Completion of Industrial Training Letter
Appreciation
Abstract
Table of content
Chapter 1 : Introduction
1.1 Preliminary
11
1.2 Industrial Training Objectives
12
1.3 Report Objectives
14
1.4 Importance of Industrial Training
15
Chapter 2 : Company Background

2.1 History of PETRONAS
16
2.2 History of Melaka Refinery
17
2.3 Board of Directors
19
2.4 Organization Chart of PP(M)SB
20
2..5 AMT 4 Mechanical Organization chart
21
2.6 Basic function of plant division
22
2.7 Mission and vision
23
2.8 Shared Values
23
2.9 PPMSB Facilities
24
Chapter 3 : Weekly Summary

3.1 Weekly summary of industrial training
28
Chapter 4 : Technical Report

4.1 Pump
4.1.1 Introduction
36
4.1.2 Type of pump

4.1.2.1 Centrifugal pump
37
4.1.2.2 Positive Displacement pump
40
4.1.3 Centrifugal Pump Operation
15
4.1.3.1 Pre-operational check
47
4.1.3.2 Pump preparation and start up procedure
48
4.1.3.3Pump inspection during operation
49
4.1.3.4 Shutting down the pump
49
4.1.4 Pump maintenance

4.1.4.1 Pump fault diagnosis and troubleshooting in the field
50
4.1.4.2 Inspection: Daily/Monthly/Half-yearly/Yearly
51
4.1.5 Positive displacement pump operating procedure

4.1.5.1 Start-up procedure
52
4.1.5.2 Shutdown procedure
53
P O L I T E K N I K U N G K U O M A R | 10
4.1.5.3 Control of positive displacement pump
53
4.1.5.3 Positive displacement pump troubleshooting 54
Chapter 5 : Findings and Recommendations

5.1 Findings
57
Chapter 6 : Conclusion
59
Bibliography/ Reference
60
Appendix
62
CHAPTER 1
INTRODUCTION
Industrial Training module is main component in the learning curriculum for

Polytechnic of the Ministry of Higher Education (MOHE). Industrial training is one
of the compulsory courses for every polytechnic student under the Ministry of
Higher Education (MOHE) Malaysia. Every student bounds to be involved in
industrial training for one whole semester in order for him or her to get his or her
diploma certificate.
1.1
Preliminary
The industrial training was carried out at a firm or an organization whether
the student chooses it or it is given to them for one whole semester. The main
purpose of the industrial training is to produce graduates who ready and capable to
face their profession academically or non-academically with high professionalism
appearance.
Other than that, the industrial training exposes the students about the real
situation of the working class citizen. The industrial training also helps in developing
social skills of the students.
1.2
Industrial Training Objectives
1.2.1
To expose the students to the real life working experience and

expending their knowledge in their specific field.
i.
Students will further learn about their real life profession.

They will also learn what they need to do in order to finish
their works. This will produce a well-prepared student as they
may fit easily in and fulfill the demands of their profession
after they finish their course.
1.2.2
To make use of the theory students learned at the polytechnic
i.
Students are only exposed to the basic theory needed in the

fields of their own. These theories were mainly according to
the books. By involving in industrial training, students may
experience real life situation in their fields of work. This will
cause the students make use of their knowledge in order to get
their work done.
1.2.3
To produce trustworthy workers with high responsibility and able to

cooperate with other staffs.
i.
All tasks given by the supervisor must be completed with a

sense of trustworthy and full responsibility. This attitude is
very important to ensure all business entrusted to the students
were carried out flawlessly. At the same time it will train
students being honest not just to themselves but others as well.
1.2.4
Enhance students confidence at the end of the training
i.
During industrial training, students will be exposed to variety

of problems. By the experience gained during the industrial
training, the students will feel more confident in their study
and work. Whenever the students overcome the problems they
faced during industrial training with high spirits and skills,
will cause increment in their level of confidence.
1.2.5
Learn to interact with superior officer
i.
During training, students will get the opportunity to interact

with upper management such as engineer, director, consultant
and others. With this opportunity, students will be able to
associate and discuss with them in a closer and proper way.
Students should use this opportunity as it may not come easily.
1.2.6
Increase students interest and curiosity
i.
During industrial training, students will face many new things.

This will enhance the curiosity of students. Other than that,
real life exposure which given to the students will also
increase students interest towards their field of studies.
1.3
Report Objectives
1.3.1
The objectives of the report enable the students :
i.
To provide a work document effectively.
ii.
To produce students those are responsible for their works by

providing enough evidential documents that related to work.
iii.
To expose the students on how tom provide a proper

document.
iv.
To build self-confidence of the students during training period.
v.
To complete the perquisite for the student to pass industrial

training successfully.
1.4
Importance of Industrial Training
1.4.1
Industrial training are important to the students in many aspects. This

is because this module was created to give benefit to students,
especially who take up studies in polytechnic KPTM. Among the
importance is:
i.
To produce employees that are fully disciplined after they have

graduated from the polytechnic KPTM. This can be seen
through the students who take part in the industrial training,
they are not only bound to the rules set by the polytechnic but
also rules fixed by the organization that students take their
industrial training at.
ii.
To produce employees that are skillful and ready to work

within they take their first step to the working world. By
involving in certain industrial training at the organization
given to them,student will be more skillful in carrying out a
job after they were explained on how to do the job by a more
experienced co-worker.
iii.
Students who went through industrial training will be more

mature in conducting the works given to them.
iv.
Students will also be more knowledgeable and understanding

about matters related to their field of study after the practical
lessons
CHAPTER 2
COMPANY BACKGROUND
2.1
History of PETRONAS
Petroliam Nasional Berhad (PETRONAS) was established in 1974 and is

Malaysias leading international petroleum corporation. The company source,
produce and deliver products to meet societys growing energy needs while playing
the role of custodian for Malaysias national reserves.
The growing demands of energy inspires and strengthens our purpose to deliver the
most essential and reliable sources of energy and the company aim to sustain that for
decades to come.
They apply innovative approaches to technology which helps them unlock and
maximize energy sources from even the most remote and difficult environments.
Their fully integrated pipeline and value chain spans from exploration to marketing,
logistics to technological infrastructures, with operations in over 50 countries around
the world. Throughout their rapidly expanding network, they constantly find new
ways to reinforce their responsibility to the environment and communities where

they operate.
2.2
History of Melaka Refinery
Petronas Penapisan (Melaka) Sdn. Bhd. [PP (M) SB], located in Sungai Udang,
Melaka, is a wholly-owned subsidiary of Petroliam Nasional Berhad or PETRONAS,
the
national oil corporation. PP (M) SB manages and operates the refinery complex in
Malacca. PP (M) SB is the second refinery complex in the country after the first
refinery
which was constructed in Kerteh, Terengganu. Petronas also has a third refinery in
Engen, South Africa. PP (M) SB consists of Petronas Second Refinery Phase 1 (PSR
1)
and Petronas Second Refinery Phase 2 (PSR 2). The Malacca refinery complex is
now
within an area of 926acres and is still expanding.
PSR 1, wholly owned by Petronas, was built-in in September 1987. Plant
operations were commissioned in 1994 processing local sweet feedstock
(sulfur<0.5wt
%) for the design capacity of 100,000 barrels per day (BPSD) utilizing
hydroskimming
configuration (sweet train).The main process units at PSR1 include:
1)
2)
3)
4)
5)
6)
7)
Crude Distillation Unit

Naphtha Hydrotreating Unit
Catalytic Reforming Unit with Continuous Catalytic Regenerator
Saturated Gas Concentration Unit
Sour Water Stripping Unit
Kerosene & Heavy Naphtha Treating Unit
Mercury Removal Unit
PSR 2, incorporated in May 1991, is operated by the Malaysian Refining

Company (MRC). MRC consists of Petronas (53%) and Conoco-Phillips (47%).
Production for PSR 2 with deep conversion facilities, started in 1998 with a capacity
of
100,000 BPSD processing up to 70%sour feedstock(sulfur>2.5wt%), mainly middle
east
crudes, utilizing complex conversion configuration(sour train).The main process
units at
PSR 2 include:
1) Crude and Vacuum Distillation Units
2) Naphtha Hydrotreating Unit
3) Catalytic Reforming Unit with Continuous Catalyst Regenerator
4) Saturated Gas Recovery Unit
5) C6 Isomerization Unit
6) LPG and Naphtha Treating Units
7) Kerosene Treating Unit/Caustic Neutralization Unit
8) Distillate Hydrotreating Unit
9) Hydrocracker Unit
10) Delayed Coker Unit
11) Hydrogen Production Unit
12) Hydrogen Collection and Distribution System
The two refineries, PSR1 and PSR2 are designed to operate as an integrated
complex with common utility, offsite and marine facilities.
2.3
Boards of Director
1) Tan Sri Mohd Sidek Hassan (Chairman of the Board)
2) Tan Sri Dato Shamsul Azhar Abbas (President and Group Chief
Executive Officer)
3) Tan Sri Dr Mohd Irwan Serigar Abdullah
4) Tan Sri Amirsham A.Aziz
5) Datuk Muhammad Ibrahim
6) Dato Mohamad Idris Mansor
7) Tan Sri Dato Seri Hj Megat Najmuddin Datuk Seri Dr Hj Megat Khas
8) Krishnan CK Menon
9) Datin Yap Siew Bee
10) Datuk Mohd Omar Mustapha
11) Datuk Wan Zulkiflee Wan Ariffin
12) Dato Wee Yiaw Hin
13) Abdul Rahman Musa (Secretary)
2.4
Organization Chart of PP(M)SB
Managing Director/CEO
Other Departme
Plant Division
Other Departments
Technical Services Department
Health, Safety, Environment and Security Departmen
Technology Department
Production Department
Laboratory Department
Engineering Department
Refinery Planning Department

Materials, Corrosion and Inspection Department
Operational Perfomance Department

Project Engineering and Services Department
2.5 AMT 4 Mechanical Organization Chart
2.6 Basic Function of Plant Division
Department
Production
Function
All process operations including ultilities, storage and
shipping of feed and products are taken care by this
Engineering
department
Plant asset management, major maintenance,
maintenance engineering, reliabilitymanagement and
Refinery Planning
turnarounds are taken care by this department

Feed and product shipping schedules and plant
Operational Perfomance Improvement
productions are taken care by this department

This department takes care of benchmarking,
knowledge management in the refinery
Table 1
2.7
Vision and Mission
These statement define PETRONAS as an organisation, guiding our corporate

activities and policies, setting our course for the future.
2.7.1 Vision statement

To be a Leading Oil and Gas Multinational of Choice
2.7.2 Mission statement

2.7.2.1 We are a business entity
2.7.2.2 Petroleum is our core business
2.7.2.3 Our primary responsibility is to develop and add value to this
national resource
2.7.2.4 Our objective is to contribute to the well-being of the people
and the nation
2.8
Shared Values
Our values are embedded in our culture as the backbone of our business conduct,
reflecting our sense of duty and responsibility in upholding our commitment towards
contributing to the well-being of peoples and nations wherever we operate.
2.8.1 Loyalty
Loyalty to nation and corporation
2.8.2 Integrity
Honest and upright
2.8.3 Profesionalism
Committed, innovative and proactive and always striving for

excellence
2.8.4 Cohesiveness
United in purpose and fellowship
2.9
PP(M)SB Facilities
2.9.1 Storage Tank
Fig. 2.1
2.9.2 Jetty
2.9.3 Tank Truck Loading Rack (TTLR)
Fig 2.3
2.9.4 Multi Product Pipeline
Fig 2.4
2.9.5 Sulphur Handling
Fig. 2.5
2.9.6 Coke Handling
Fig. 2.6
2.9.7 Fire Station
Fig 2.7
2.9.8 Laboratory
Fig 2.8
CHAPTER 3
WEEKLY SUMMARY
3.1
Introduction
In undergoing industrial training, students are disclosed with a whole lot of new
things. Apart from practicing what we had learnt in polytechnic, students also gain
the opportunities to experience real work according to their courses themselves by
doing assignment that have been provided by their supervisor. By doing so, students
are able to increase their self-confidence upon entering the real working world on
future. On the other hand, students had to obey every rule provided by the firm and
polytechnic at the same time which will improve their discipline.
3.2
Following is the summary of all the activity carried out during training period
weekly.
Week 1
(23th June- 27th June 2014)

1) Briefing and safety induction by Health, Safety, Environment and Security
Department.
2) Repair leaking pipe
3) Attend ISPS (The International Ship and Port Facility Security Code) briefing
to enter Sungai Udang Port (Jetty)
4) Replace conveyer motor gear oil
5) Changing pre-filter O ring
6) Install and test pump diaphragm pump
Week 2
(30th June- 4th July 2014)

1) Rectify penstock gate valve (hard to open)
2) Service diaphragm pump
3) Change strainer pre-filter
Week 3
(7th July- 11th July 2014)

1)
2)
3)
4)
5)
Service diaphragm pump

Remove host box
Change rupture disc
Change strainer pre filter
Repair skimmer leak
Week 4
(14th July- 18th July 2014)

1) Repair packing leak
2)
3)
4)
5)
6)
Perform strainer cleaning job

Install new belting for compressor
Replace oil seal
Dismantle air winch
Week 5
(21st July- 26th July 2014)

1)
2)
3)
4)
5)
6)
7)
Fix back air winch

Disassemble diaphragm pump (body leak)
Recitfy penstock gate
Connect 3 hose
Perform strainer cleaning
Repair N2 pipeline leak (wrapping)
Week 6
(28th July- 1st August 2014)
1) Replace rubber coupling
2) Perform alignment on mixer motor
3) Preventive maintenance job on vessel
Week 7
(4th August- 9th August 2014)

1)
2)
3)
4)
5)
6)
7)
Flange modification for submerge pump

Install submerge pump
Test run submerge pump
Replace oil seal leak
Replace sand filtering tank floater
Rectify ball valve hard to operate
Week 8

1)
2)
3)
4)
5)
Replace sand filtering tank floater

Preventive maintenance on MOV stem
Remove blind flange
Replace new penstock gate
Week 9
(18th August- 22nd August 2014)

1)
2)
3)
4)
Install spool (12X 300)

Reinstall isolation for pipeline discharge
Rectify shaft hard to rotate
Replace new copper steam line tubing
Week 10

1)
2)
3)
4)
5)
6)
7)
Preventive maintenance on pump

Install spool and hose for Bern valve
Help operation supervise contractors doing housekeeping
Replace eliminator gate valve
Repair skimmer leak (wrapping)
Replace plummer block bearing
Week 11
(1st September- 5th September 2014)

1)
2)
3)
4)
Replace plummer block housing

Test run conveyer and housekeeping on coke tower
Week 12
(8th September- 12th September 2014)

1)
2)
3)
4)
Preventive maintenance job on pump

Repair skimmer hand wheel and gear
Rectify coke shiploader deduster(motor jammed)
Week 13

1)
2)
3)
4)
5)

Preventive maintenance job on compressor
Layout 3 hose
Install strainer for diaphragm pump
Week 14

1)
2)
3)
4)
5)
6)

Relocate 2 way valve for isolation
Reconnect water draw spool
Install mesh strainer
Monthly HSE Meeting
Week 15
(29th September- 3rd October 2014)
1)
2)
3)
4)
5)
6)
7)
Replace oil seal on deduster motor

Replace damaged and old hose box
Install new platform for diaphram pump
Remove flexible hose
Replace decicent for dryer
Week 16
(6th October- 10th October 2014)

1) Service diaphragm pump
2) Replace submerge pump discharge hose
3) Replace sulphuric acid vessel sight glass
Week 17
(13th October 17th October 2014)

1)
2)
3)
4)
5)

Rectify flange leak
Test run mixer motor
Change strainer pre-filter
Week 18
(20th October- 24th October 2014)

1) Replace gasket (vessel leak)
2) Preventive maintenance job on pump
3) Install mesh strainer
Week 19
(27th October -31st October 2014)

1)
2)
3)
4)
5)

Drop spool for water draw
Install mixer belting
Install gate valve (36 X 150)
Mobilize diaphragm pump
Week 20
(3rd November- 7th November 2014)

1) Preventive maintenance on loading arm
2) Repair bucket strainer leak
3) Rectify pin hole leak at 10 line
CHAPTER 4
TECHNICAL REPORT
4.1.1 Pumps Introduction

Pumps are used to force a liquid to flow from a point of low pressure to a point of
higher pressure.
There are two general classification of pumps:
1) Centrifugal pumps
2) Positive displacement pumps
Centrifugal pumps are the type most widely used in the Oil and Gas Industry. They
are used for transferring hydrocarbon liquids of all types, crude oil, gasoline, naphtha
as well as for more general use for example for utilities water supply. Centrifugal
pumps are available in large range of sizes from 2 gals per minute up to 100,000 gals
per minute and for discharge pressures from a few psig to several thousand psig.
Positive displacement pumps also find wide usage in the Oil and Gas Industry. They
are generally more efficient than centrifugal pumps and often find application where
precisely measured quantities of liquid are required. However they are not as
adaptable and more expensive than centrifugal pumps.
4.1.2 Types of pumps
4.1.2.1 Centrifugal pumps
Centrifugal pumps can be either horizontal or vertical. The horizontal pumps

requires a firm foundation for its mounting, whereas the vertical pumps can be
attached to the piping with a minimum of support beneath the pump. The horizontal
pump is a more rugged pump which will resist most vibration present.
Vertical pumps are commonly used in a process plants in locations where

vibration is not a problem. Another advantage of the vertical pump is that the
alignment between the motor and pump is much easier to maintain than that of
horizontal pump.
Multi-stage pumps
Pumps with more than 1 impeller are called multi-stage pumps. Each impeller is
referred to as a stage. A pump with 5 impeller is a 5 stage pump.
There are 3 common types of multi-stage pumps:
Fig 4.1.2.1
1) Submersible
The submersible pump is an integral pump-motor unit in a sealed enclosure.

In a well, the pump is inserted inside the casing. An electric cable runs from
the surface to the motor. These pumps are used for lifting water or oil from
any depth. The pump capacity is limited by the size of the casing. An electric
power source is required at the surface to operate the pumps.
Fig. 4.1.2.2
2) Can-type vertical
Can-type vertical pumps are used to lift liquids from sub-surface sources such
as sumps and caissons. The pump driver is located at or above the liquid
surface, and the shaft extends from the driver to the pump, which may be
located some distance below the liquid surface. Multi-stage can-type pumps
are frequently installed on offshore platforms to provide and emergency
firewater supply.
Fig 4.1.2.3
3) Horizontal multi-stage
Horizontal multi-stage pumps are used in process plants and oil pipelines
where the pump must increase the liquid pressure several hundred psig. There
is no theoretical limit to the number of impellers in a horizontal pump, but
more than 8 are seldom used.
4.1.2.2 Positive Displacement Pumps
There are two general classifications for Positive Displacement pumps
1) Reciprocating
2)
Reciprocating pumps are classified by the features:
i) Drive end (power or direct-acting)
ii) Orientation or centerline of the pumping element (horizontal or
vertical)
iii) Number of discharge stroke per cycle of each drive rod (single-acting
or double-acting)
iv) Configuration of the pumping element (piston, plunger, or diaphragm
pump)
v) Number of drive rod (simplex, duplex, multiplex)
The number of combination is almost endless. The power provided by a motor or
engine in a rotary can be changed into reciprocating motion in the same mechanical
manner that an automobile engine changes reciprocating power strokes into a rotary
movement of the crankshaft. This action is reversed in a power driven reciprocating
pump.
Example of reciprocating pumps:
Fig 4.1.2.2.1
i)
Gear driven piston pump

Piston are used for powered pumps in a lower pressure service
Fig. 4.1.2.2.2
ii)
Plunger pumps
To obtain higher pressure than piston pump, another type of pump end-a
plunger is used
Fig. 4.1.2.2.3
iii)
Diaphragm pump
Compressed-air operated diaphragm pumps are widely used in oil and gas
process plants for handling slurries, mud etc. a diaphragm of flexible nonmetallic material can better withstand corrosive or erosive action than
metal parts of some reciprocating pumps.
3) Rotary
Rotary pumps consist of a fixed casing containing gears, vanes, pistons,
cams, segments, screws operating with minimum clearances. Instead of
throwing the liquid as in a centrifugal, a rotary pump traps it, pushing it
around the closed casing, much like a piston of a reciprocating pump. But
unlike a piston pump, a rotary pump discharges a smooth flow.
Example of rotary pump:
Fig 4.1.2.2.4
i)
External gear pump
Fig 4.1.2.2.5
ii)
Internal gear pump
Fig 4.1.2.2.6
iii)
Lobular pump
These resemble the gear-type pumps in a action and have 2 or
more rotors cut with 2, 3, 4, or more lobes on each rotor. The
rotors are synchronized for positive rotation by external gears.
Because liquid is delivered in a smaller volumes but at greater
frequency than in the gear pump, flow from lobular type pump is
not quite so constant as from the gear type.
Fig 4.1.2.2.7
iv)
Screw pumps
These have one, two, or three suitably threaded screws turning in a
fixed casing. A large number of designs are available for various
applications.
Single-screw pumps have a spiraled rotor turning eccentrically in
an internal-helix stator or liner. The rotor is metal while the helix
is hard or soft rubber, depending on the liquid handled.
Two and three-screw pumps have one or two idlers, respectively.
Flow is between the screw threads, along the axis of the screws.
Opposed screws may be used to eliminate end thrust in the pump.
Fig 4.1.2.2.8
v)
Vane pumps
Sliding-vane pumps use vanes that are held against the casing bore
by centrifugal force when the rotor is turned. Liquid trapped
between two vanes is carried around and forced out the pump
discharge.
4.1.3 Centrifugal Pump Operation
4.1.3.1 Pre-operational Checks
Before actually starting up the equipment, the following is a checklist of items that is
recommended to be looked at.
1. For pumps with double mechanical seals or packing with external gland oil,
the gland oil supply piping should be cleaned by oil or solvent flushing prior
to connecting to the pump.
2. For pumps with tandem mechanical seals, the overhead reservoir and all flush
oil supply piping should be thoroughly cleaned by oil flush prior to
connecting to the pump.
3. It is important for good seal or packing performance that dirt or foreign debris
not be introduced into the seal or packing cavity.
4. The flushing and steaming of pumps with single or tandem mechanical seals
should be held to a minimum period of time. This will minimize the amount
of debris entering the seal cavity, and prevent the destruction of the static seal
5.
element by overheating.
All cooling water piping on pumps and turbines should be flushed and
connected prior to operation.

6. Motor drivers should be powered-rotated to check for proper direction of
rotation prior to coupling to the driven equipment.
7. Turbine over speed trip setting and governor operation must be checked prior
to coupling to the driven equipment.
8. Gear type coupling should be packed with the proper grease and the pump
and drive coupled up. Recheck the coupling float and verify that it is within
the coupling manufacturers tolerances.
9. The coupling guard should be installed prior to rotating any shaft under
power.
10. If a separate lube oil system is provided, the system should be cleaned and
flushed and all alarms and shutdowns set and tested prior to operation of the
equipment.
4.1.3.2 Pump preparation and start up procedure

After the pump has been installed and coupling alignment completed, the appropriate
check may be consulted and these step should be followed for a successful startup:
1. Pump and driver should be checked for sufficient and proper lubrication.
2. Driver should be checked for correct rotation.
3. Pump suction valve should be fully opened (check pump and piping for
leaks)
4. Pump case should be vented (open vent at top of pump casing until all air is
expelled from casing)
5. If product is hot, ample time should be allowed for pump case to heat up
(pump case and rotating assembly could distort from uneven heat transfer)
6. Before starting , rotate pump shaft by hand (should be free, no rubbing)
7. Crack open discharge valve-dont fully open (a centrifugal pump used less
horsepower at start up with the discharge valve nearly closed; also this
practice will prevent initial cavitation)
8. Start pump, watch discharge pressure gauge, and as soon as pump pressure
stabilized, open discharge valve slowly. Watch discharge gauge; discharge
pressure will fall off for a few turns of the valve until existing heat condition
are met. Once pressure stabilized, you can fully open the discharge valve.
Important! Never allow pump to run too long with discharge valve closed.
4.1.3.3 Pump inspection during operation

1. During operation, a centrifugal pump requires occasional inspection
2. Make sure that there is flow as the discharge valve is opened by watching for
a drop in discharge pressure.
3. Watch for fluctuation in suction and discharge pressure to make sure the
pump does not cavitate.
4. After the pump has run for a few minutes, the operator should touch the pump
and motor bearing to determine if they are over-heating
5. The mechanical seals should be checked for leakage particularly during the
first hours of operation. A minor leak through the seal usually stops after a
short time, but if it continues, the pump should be stopped and the seal fixed.
6. When operating the pump at a discharge below the rated point, the motor
should be watched carefully. The discharge valve should be throttled to build
up head to a safe point. Should the low heat condition persist, the pump
should be shut down. Centrifugal pumps should not be operated at greatly
reduced capacity or with the discharge valve pinched because the energy
required to drive the pump converted into heat and the temperature of the
liquid may reach the boiling point. Furthermore, many pumps are subject to
flow instability at low flows.
4.1.3.4 Shutting down the pump
The general procedure in stopping the pump are as follows:

1.
2.
3.
4.
Open the valve in circulating line.

Close the discharge gate valve slowly.
Stop the motor
Open the warm up valve (for hot liquid) if the pump is to be kept at operating
temperature.
5. Close all the valve that supply cooling water to the bearings, housings or
water cooled stuff boxes.
6. If the sealing liquid supply is not required while the pump is idle, close the
valve in this supply line.
7. Close the suction valve, open the drain valves, as required by the particular
installation or if the pumps is to be opened up for inspection.
4.1.4
Pump maintenance
4.1.4.1 Pump fault diagnosis and troubleshooting in the field
Severe operating condition in most refineries and chemical plants subject

process pumps to high temperatures, abrasion, corrosion and premature
bearing and mechanical seal failures.
Damage to the pump can occur not only inside the mechanical surfaces, but
on the outside as well. Surrounding atmospheric condition can also shorten
the life of any pump, especially in corrosive environments. The life
expectancy of pumps and mechanical seals in this type of environment is very
dependent on proper maintenance procedures.
Many mechanical seal failures have been the results of wear deterioration of
pump bearings or internal pump components. Troubleshooting pump and
mechanical seal difficulties should begin at the pump while it is installed and
running. Maintenance and operating personnel need to determine first if a
process deficiency might be causing pump or mechanical seal problems. The
investigation should involve a thorough study of pump hydraulics to
determine if the pump is performing as per design. The pump should be
checked for excessive vibration, shaft deflection, noisy bearings, and
excessive temperatures. If pump hydraulic appear to be normal, but the pump
is noisy and vibrating, it is quite possibly that the pump could be misaligned,
or the coupling could be faulty or possibly the pump or motor bearings are
defective. If the pump bearings have been subjected to severe vibration, the
pump will have to be removed to the shop for repairs, and if the mechanical
seal is leaking it will also need replacing.
4.1.4.2 Inspection: Daily/ Monthly/Half-yearly/Yearly
Intervals
Daily
i.
ii.
iii.
iv.
v.
Routine
Check pump for noisy bearings and cavitation noise
Check bearing oil for water, discoloration and contamination
Feel all bearings for temperature. Check oil level
Check packing glands for excessive leakage
Inspect bearings and oil rings through filling ports. Wipe
vi.
bearings cover clean

Check for oil leaks at gaskets, plugs and fittings
vii.
Self flushed pumps-hand check flush line temperature to

determine flow through line. External flushed pumpsdetermine if flow indicator and needle valve adjustment is in
Monthly
Yearly
viii.
i.
ii.
iii.
good condition.
Determine if mechanical seal condition is normal
Add oil if required
Check packing gland for shaft wear
Ascertain that oil level is correct distance from shaft center
iv.
line. Adjust oiler as required

Clean out debris from bearing brackets. Drain hole must be
v.
vi.
i.
ii.
iii.
iv.
open
Replace guards (repair if required)
Determine if pump unit requires general cleaning by others
Check impeller wear and wear rings
Check bearing wear
Do seasonal oil change-out if required by Lube Guide
Dial indicators check coupling alignment in coupled condition.
Use special coupling indicator clamps where possible. Ensure
v.
that thermal growth allowance is correct

With indicator clamped to coupling, depress and lift on each
coupling and note dial indicator change. Determine if
vi.
deflection is normal for this machine. Check coupling for wear

Dial indicator check axial float of pump and driver shafts in
vii.
similar manner
Replace gasket. Clean and paint pump housing
Table 4.1.4.1.1 Recommended preventive Maintenance Checks for Centrifugal

Pumps
4.1.5
Positive displacement pump operating procedure
The following procedures should be used as a guidelines only. Actual procedures

may vary from one pump model/manufacturer to another.
4.1.5.1 Start-up procedure
The procedure of for starting a positive displacement pump is shown below.

Prior to start-up the following items should be checked:
i.
If a lubrication system is present, check to see that it contains
ii.
lubricating oil.
Check valves in the suction line and discharge line from the pump to
see that liquid can enter the pump and discharged liquid is routed to
iii.
its correct location.

Start the driver (motor or engine)
Caution:
Before starting a positive displacement pump, valves in the suction and
discharge line on the liquid end should always be open. If the pump is started
with a closed discharged valve, pressure in the discharge line may rise high
enough to burst the line.
4.1.5.2 Shutdown procedure
A positive displacement pump is shut down by stopping the driver.
4.1.5.3 Control of Positive Displacement Pumps
Positive displacement pumps are controlled so that they pump the volume of
liquid available to them. In some operating situations, the pumps operate at a
constant flow rate, and no control is provided. An example of this type of
operation are glycol pumps, these pumps usually have a motor drive and they
operate at a constant speed.
There may be occasions when flow from a constant speed pump needs to be
reduced. The only practical method common to all positive displacement type
pumps is to open valve in a bypass line so that some of the discharge liquid
flows back into the suction line.
4.1.5.4 Positive Displacement Pump Troubleshooting
Troubleshooting any problem is a trial and error process in which each

possible cause of the problem is checked by the technician until the specific
cause is found. The most important aspect of troubleshooting is one of
finding the cause and eliminating it rather than treating the symptoms. The
following table lists the procedures for troubleshooting the most frequent
problems that occur on reciprocating pumps.
PROBLEM
Low pump capacity
CAUSE
1. Driver low speed
2. Cavitation or vapour
lock. Pump vibrates
and discharge
pressure varies
3. Leaking suction/
CORRECTIVE ACTION
Check for loose, worn, or broken
belts and correct.
Increase liquid level in vessel
being pumped to increase Net
Positive Suction Head(NPSH).
discharge pump
valves or piston
rings. Pump is noisy
4. High head pressure.
Inspect and repair.
Suction pressure is
low. Pump stalls
5. Pump bypass valve
open or relief valve is
Raise suction pressure or lower

discharge pressure.
leaking
Close bypass valve or repair

Frequent packing
failure
1. Packing not properly

installed, or wrong
leaking relief valve.

Replace packing following
suppliers recommendations.
material is used
2. Lack of lubrication
3. Packing and rod are
hot
4. Worn rod
5. Liquid contain solid
particles
Replace existing lubricator install

new one.
Adjust packing gland so that drip
leak occurs.
Replace rod.
Frequent failure of
1. Pulsation. Pump
valves or piston
vibrates and is noisy

2. Liquid contains solid
rings
particles
3. Vapour
lock
4. Anchor bolts are
Bearing or
crankshaft failure on
motor or engine
driven pump
Install strainer in suction line.

Install pulsation dampener
Install strainer in suction line
loose and pump
Raise liquid level in vessel being
vibrates
pumped from, to increase NPSH
1. Lack of lubrication
2. Belts are too tight
3. Main bearings are too
tight or too loose
4. Misalignment
Tighten anchor bolts

Keep crankcase oil at proper
level.drain water from crankcase
Adjust belts
Check bearing clearance and add
between pump
or remove shims to
crankshaft and driver.
manufacturers specifications
Align to manufacturers
specification
Table 4.1.5 .4.1 Troubleshooting reciprocating pumps
8)
CHAPTER 5
FINDINGS AND RECOMMENDATION
While undergoing a 20 weeks industrial training at Petronas Penapisan (Melaka) Sdn

Bhd, there are a lot of knowledge that I have learnt, regardless of knowledge for
performing maintenance itself. With the implication of industrial training, students
get to experience the real nature of working environment. This enable students to
instill a certain quality to themselves and will increase their self-confidence. Other
than that, by implementing industrial training, students were able to adapt oneself
with problems that often faced by every employee, which will enable student to think
maturely and give the best effort to carry out their duty. Everything that has been
learned by the students while undergoing the industrial training will be useful to
them when they reach the working world in future.
Apart from that, there are also a few matters that need to be improved by either the
Polytechnic or the firm or the company itself. Among the improvement that I wish to
suggest are:
1. Fully implementation of English language for lecturer in class room while

they are teaching their students. This because most of the phrase, tools and
instruction/manual that have been provided by the manufacturer of the
machine was in English. Most of the polytechnic students are less skilled in
English conversation and this will affect their social ability when they need to
interact with foreigner superior of their company. I really hope that the
management of Polytechnic will encourage more students and lecturer to use
English language among them.
2. The management of polytechnics should planned more visit to the places

where trainees are undergoing the industrial training as often as 2-4 times
along the 20 weeks of training to monitor their development and to ensure
that students are improving themselves during the training.
3. The human resource and financial department should reconsider to handover

the students allowance by hand as what they have done before. Nowadays the
students receive their allowance by bank which make them have to wait for 2
weeks for the allowance bank-in process which make them difficult to
estimate their budget every month. The students need to submit their
timesheet early every month but they need to wait longer to receive their
allowance not as before the allowance was given by hand at financial
department every 7th date of the month. Hope the company will take note with
my suggestion.
Generally by undergoing industrial training, students has been given a valuable
experience and the understanding on the relationship between what they had learned
theoretically with what they need to do practically. However, during this industrial
training period also the students had been given opportunity to adapt themselves with
new discovery that could not be achieved at polytechnic.
CHAPTER 6
CONCLUSION
After undergoing 20 weeks of industrial training at Petronas Penapisan (Melaka) Sdn

Bhd, there are a lot of new knowledge that can be learned and I get to understand
altogether on how this firm plays an important role in industrial field as they provide
Oil and Gas supply to the entire peninsular Malaysia. All the exposure that have been
provided by PPMSB staff to me about working and technical aspect was a very
meaningful knowledge to me in order to prepare myself before stepping into the real
working world in future. I hope with the implication of the Industrial Training there
will be no more anomalous feelings when the students started working after they
have finished they study later. All the staff at PPMSB have been very helpful and
very supportive by providing healthy environment while working with them. They
provide me a lot of exposure and experience in term of references, procedures and
safety related to the job or assignments that have been provided by the supervisor.
Other than that, the exposure of site visit, meeting atmosphere and so on was the best
experience that could not be gained by learning in the classroom. All the experience
that been gain at this firm provide me the picture of the real job for the mechanical
technician about the maintenance work that was conducted in Oil and Gas industries.
Lastly students involvement in industrial training like this can prove and further
strengthen students identity by undergoing training at the technical field, at the same
time making Polytechnic as practical platform of education. Apart from that, the
format report that needs to be done by students after undergoing industrial training
also trained each of the student in preparing a technical report that is complete,
compact and in a right order that can be made as an important knowledge when they
face the real situation while they were working later on. This fit with the polytechnic
objective which to produce a workforce that are high in quality and partially
professional in this country.
Bibliography/ References
1.
2.
3.
4.
Hj Jailani Ismail, Single Stage Centrifugal Pump, INSTEP, Batu Rakit, 2007
www.petronas.com.my/about-us/our-leaders/Pages/board -of-directors.aspx
http://en.m.wikipedia.org/wiki/Pump
Philip L. Skousen, Valve Handbook Third Edition, McGraw Hill, 2011
APPENDIX

Jabatan Kerjuruteraan Mekanikal Politeknik Ungku Omar Ipoh, Perak Darul Ridzuan

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POLITEKNIK UNGKU OMAR| 1

JABATAN KERJURUTERAAN MEKANIKAL

LAPORAN LATIHAN INDUSTRI

MUHAMMAD HIDAYATURRAHMAN B RAHMAT

PETRONAS PENAPISAN (M) SDN BHD

POLITEKNIK UNGKU OMAR| 2

POLITEKNIK UNGKU OMAR| 3

POLITEKNIK UNGKU OMAR| 4

POLITEKNIK UNGKU OMAR| 5

POLITEKNIK UNGKU OMAR| 6

POLITEKNIK UNGKU OMAR| 7

POLITEKNIK UNGKU OMAR| 8

Completion of Industrial Training Letter

1.2 Industrial Training Objectives

1.3 Report Objectives

1.4 Importance of Industrial Training

Chapter 2 : Company Background

2.2 History of Melaka Refinery

2.3 Board of Directors

2.4 Organization Chart of PP(M)SB

2..5 AMT 4 Mechanical Organization chart

POLITEKNIK UNGKU OMAR| 9

2.6 Basic function of plant division

2.7 Mission and vision

2.8 Shared Values

2.9 PPMSB Facilities

Chapter 3 : Weekly Summary

Chapter 4 : Technical Report

4.1.2 Type of pump

4.1.2.2 Positive Displacement pump

4.1.3 Centrifugal Pump Operation

4.1.3.1 Pre-operational check

4.1.3.2 Pump preparation and start up procedure

4.1.3.3Pump inspection during operation

4.1.3.4 Shutting down the pump

4.1.4 Pump maintenance

4.1.4.2 Inspection: Daily/Monthly/Half-yearly/Yearly

4.1.5 Positive displacement pump operating procedure

4.1.5.2 Shutdown procedure

4.1.5.3 Control of positive displacement pump

4.1.5.3 Positive displacement pump troubleshooting 54

Chapter 5 : Findings and Recommendations

Industrial Training module is main component in the learning curriculum for

Industrial Training Objectives

To expose the students to the real life working experience and

Students will further learn about their real life profession.

To make use of the theory students learned at the polytechnic

Students are only exposed to the basic theory needed in the

To produce trustworthy workers with high responsibility and able to

All tasks given by the supervisor must be completed with a

Enhance students confidence at the end of the training

During industrial training, students will be exposed to variety

Learn to interact with superior officer

During training, students will get the opportunity to interact

Increase students interest and curiosity

During industrial training, students will face many new things.

The objectives of the report enable the students :

To provide a work document effectively.

To produce students those are responsible for their works by

To expose the students on how tom provide a proper

To build self-confidence of the students during training period.

To complete the perquisite for the student to pass industrial