ACKNOWLEDGEMENTS

I am very grateful to ALLAH S.W.T for blessing me in finishing this industrial

training with successful complete in given time and hope this will be benefit to all.

In this opportunity, I would like to thank to my family for giving whole

heartedly morale support, motivation and encouragement in completing this final project
and also to finish my study in UMP with successful.

I wanted to thank Syarikat Air Terengganu for giving me opportunity to do and

finish my industrial training. I also would like to convey my full appreciation and
thankful to my supervisor, En Nik Izual bin Nik Irahim and En.Mohd Kepli bin Ibrahim
as industrial supervisor for their guiding and supervising my industrial training. He has
been very helpful and encourages me in finishing my industrial training. Without his
support, critics and advice I could not finish this training as presented here. I really
appreciate every advice that he give in order to train me. I also want to thank all the staff
in Syarikat Air Terengganu for advising me in order to train me. I beg for the forgiveness
to my supervisor and all the staff especially mechanical and electrical staff if there are
any mistakes and things that happen since doing my training.

Lastly I want to thank to all my friends that have given me advice and
encouragement in finishing this training. All that I stated above gives inspiration for me
to success on completing my training.

ABSTRACT
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 The main product of the Syarikat Air Terengganu is clean water. It product is
market to the whole Terengganu state. In the mechanical section the trainee was given
project to complete during the industrial training. The trainee must at least understand
the whole system of the water the water treatment plant. The systems are dividing into
section and each section has its own job requirement. The sections are intake system,
raw water treatment section, treated water section and distribution section. The project in
these sections is to understand the system of each section and do the maintenance of the
plant system. Another project is called water meter testing. This project is to test the
meter complains by the costumers and the meters sell by the suppliers.

COMPANY BACKGROUND

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 This company was formally known as Jabatan Bekalan Air Terengganu and in
1st July 1999, the Jabatan Bekalan Air Terengganu was converted to a private entity and
named as Syarikat Air Terengganu Sdn. Bhd(SATU).
Syarikat Air Terengganu Snd.Bhd (SATU) is a company that committed to
provide the safe and clean water for the customers daily used. The company is
committed in their work in order to achieve their bench mark and concord to the
MS ISO 9001: 2000.
The company prepared their own web side to give rashness to the customer for
effective services. The web side is www.satuwater.com.my and they provide facilities
such as:-
1. To check the account online.
2. To make any report.
3. To get piping people in nearing area.
The company provides various sectors and department to manage the company
smoothly and effectively. The sectors responsible to the company are:-
1. Administer section (head quarters)
2. Perhubungan awam
3. Human resource department
4. Financial department
5. Revenue sector
6. Operation and maintenance department
7. Water quality department
8. Production department
9. Distribution department
10. Construction and engineering building department
11. Mechanical and electrical engineering service department
12. Engineering program sector

ORGANIZATION CHART

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COMPANY ACTIVITY

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PMCM (PREVENTIVE MAINTENANCE, CONDITION MONITORING)

Preventive Maintenance (PM)

Preventive maintenance is a process that using tools with various functions to

show problems and performance of the component and machine while operating and not
subject to any maintenance schedule.

Pump Preventive Maintenance

Leakage checking at the gland packing

Packing must be protected using water and water pressure is enough. Allowable
leak for any pump is 60 drops per second.

Figure 1: Packing position in the stuffing box

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 Figure 2: packing position after the adjustment

Operate the pump shifty

The pumps are operating shifty in order to make the pump or machine can be
used for along time.

Pump monitoring tools checking

Monitoring tools at the pump always be checking to make sure the pump is
correctly react with the monitoring tools such as flow meter, pressure gage and lever
sensor.

Mechanical seal checking

Mechanical seal is very important component to prevent leakage at the pump.

This seal required water as the cooler.

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 Figure 3: mechanical seal

Mechanical seal have two surfaces:

1) Rotary
2) Statics
Mechanical seal required water as a cooler. The pumps installed with
mechanical seal are not allowed to be operated in the dry condition because it
will damage the seal and pump it self. Normally the seal face will reduce by
friction after some time. Inspection is needed time by time to prevent brake
down.

Figure 4: Schematic diagram for mechanical seal

Pump and motor alignment

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 If misalignment pumps and motors always happen, the whole pipe system
required an inspection. The pumps and motor need to be dissembled from the system
and alignment are required for the system.

Figure 5: Pump and motor alignment

Figure 6: Pump alignment schematic diagram

Condition Monitoring ( CM )

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 Condition monitoring is a process identifies the problems before brake down
using tools and experience. Any change at the tools or machine shows the problem
occurs. Condition monitoring can be fit as any program as:-
OSHA 1910 program compliance
ISO 9000 vendor status
Preventive maintenance
Predictive maintenance
Engineered maintenance
Total quality management (TQM)

Problem recognizing

Problem recognizing must do continuously before the brake down of the pump or
machine and equipment.

Sign of the problem.

1. Vibration: Normal sign and easy to monitor.

2. Acoustic emissions: ultrasonic sound out come from fracture.
3. Temperature increscent: occur in because of seal and bearing friction.
4. Oiling: Oiling analysis at the machine and equipment.
5. Management: Environment and work procedure influence in a work place.

1. Vibration analysis
Vibration pattern analyze shows misalignment and bearing worn away.
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 2. Temperature analysis
Temperature increasing shows problems at the bearing, slippery and electrical
wiring are not perfect.
3. Oiling analysis
Analyze the physical and chemical properties of the slippery to acknowledge any
changing. By controlling the physical and chemical properties the brake down of
the machine are prevented.

Monitoring brake down while operate.

Problems and brake down of the machine occur in situation machine or pump
still operating. It is very important to acknowledge that the machine or pump is not
working out of it capability.
Machine and structure environment observer is important while inspect the brake
down while operating such as:-
1) The whether such wind speed, wind direction and humidity.
2) Corrosive chemicals in the workplace.
3) Environment that capable of burning situation.
4) Tools and work procedure must follow the specification and the
standard operation procedure. Maintenance procedure must
follow the maintenance schedule.
5) Tools for the maintenance should be in the good condition.
6) Parameters of the chemicals and machine must precisely and not
influence the analysis.
Within various kind of monitoring condition, factors and risks of the machine
and equipment brake down are avoided. Apposition acts can be done more smoothly and
accurately.

STUDENT SELF ACTIVITY

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Project 1: Water meter test

Objective

The water meter is test because of two reasons .The first reason is, the meter is
being test when the customers complaint about the meter. Normally, the customers
complains when the customer pay more than they should. The second reason is, when
the company what to buy the new meters. The supplier will send the sample of the meter
for testing.

Theory

The allowable error for each meter is 3.0%

Formula:

Figure 7: Schematic diagram for test meter

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Figure 8: Calibrated tank

Figure 9: Test bench

Figure 10: Water meter

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 Water meter test procedure

1. Install the meter or specimen in the jig.

2. Open the main solenoid valve.
3. Flush the piping and the test meter.
4. Make sure the pipe and the meter connections do not leak.
5. Open the flushing / drain pipe to make sure there is no air trap in the pipe and
meter.
6. Close the flushing and the main solenoid valve.
7. Open the drain pipe to make sure the water volume in the tank is set to zero.
8. Take the meter initial reading.
9. Open solenoid valve and flow through the 500 liter tank.
10. Open manual valve to 500 liter tank.
11. Set the rotameter to range 1400 ~ 1000 liter per hour.
12. Flow to the 500 liter mark and stop the system.
13. Close the main solenoid valve and all manual valves.
14. Take the meter reading.
15. Record the reading into the table.
16. Drain the water collected in the calibrated tank.
17. Remove tested meter from bench.
18. Shut down all system.
19. Repeat step 1 to 18 for another meter testing.

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 Result

Serial number; A030302082

Size: 15mm
Flow rate: 1400L/h
Actual volume: 500L
Brand: GI

Final reading Initial reading Volume Error Efficiency

different
4086.4779 4085.9587 0.5192L 3.84% 96.16

Serial number; A030302137

Size: 15mm
Flow rate: 950 L/h
Actual volume: 525L
Brand: GI

Final reading Initial reading Volume Error Efficiency

different
4316.6426 4316.6993 0.0467L 91.1048% 8.8952

Serial number; SATU01K05530

Size: 15mm
Flow rate: 950L/h
Actual volume: 500L
Brand: KENT

Final reading Initial reading Volume Error Efficiency

different
1958.7434 1958.2260 0.5174L 3.4% 96.6%

Serial number; B96114705

Size: 15mm
Flow rate: 1400L/h
Actual volume: 500L
Brand: ZENER

Final reading Initial reading Volume Error Efficiency

different
0658.5000 0658.5000 0.0L 100% 0.0%

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Calculation

Error =3.84%

Conclusion

All the meters that are being test is fail. The value of the error for all meters is
above the value of allowable error.

WATER TREATMENT PLANT

Figure 11: Over view of the treatment plant

Intake system

In the intake system, it must consider the source of the water. Raw water source
use is from river and lake. The pump for the intake is installing in two ways. It is dry pit
and wet pit installations. The pump used is the intake system is submersible pump.

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Figure 12: ABS submersible pump

Figure 13: Dry pit installation

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Figure 14: Wet pit installation

Submersible pump maintenance

Procedure
a) In intake side
1) Make sure the pump is off.
2) Lift up the pump from it compartment.

b) In workshop
1) Dissemble the cap from the pump.
2) Mark the wiring system in the cap
3) Dissemble the casing
4) Dissemble the impeller from the shaft
5) Mark the wiring system
6) Dissemble the component at the shaft.(bearing, mechanical seal and est).
7) ..

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Figure 15: ABS submersible pump

Advantages of the submersible pump

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 1) Low operation cost
I. Characteristic pump that have wide impeller space capable to avoid the
pump from clogged up.
II. High efficiency of the hydraulic and electrical system
2) Dry pit installation
I. The submersible also can be installed in the dry compartment
II. The submersible pump have its own cooler system
3) Minimum maintenance
I. Easy for the maintenance and its have the monitoring system to control
the pump safety without disturbs the operation.
4) Long operation rate.
I. Used the mechanical seal as a sealing and can be operate for along term.

Component in submersible pump

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Figure 16: ABS submersible pump

1) Motor
All motors are build in water prove and from squirrel cage type, stator wound.
Stator coil are covered by the insulator in to class H phase. The motor also
already installed with the thermal sensor system.
2) Bearing
Bearing is installed above and bellow the motor. The life of each bearing is
50000 hours.

3) Mechanical Seals.
i. High thermal shock resistance
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 ii. Excellent chemical resistance range: ph 2 to 10
iii. No glue, solder or shrink-joints
iv. Bellow-design shelters shaft area
v. High abrasion resistance
vi. Excellent heat transfer

Figure 17: Mechanical seal

4) Shaft.
Stainless steel shaft is design to give tenacity to the bearing and mechanical seal
and the vibration is avoided and operate in silent.

Figure 18: Shaft

5) Impeller
Strong impeller and wear ring is design is to give good flow.

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 Figure 19: Impeller
6) Thermal sensor
Thermal sensor is installed in every phase will give warning or shut down the
system automatically if the before it reach the maximum allowable temperature
and cause the brake down.

Figure 20: Thermal sensor

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