INDUSTRIAL TRAINING REPORT

Haisan Resources Sdn. Bhd.

(5 December 2011) (24 February 2012)

STUDENT NAME: NOR SYAZWANI BINTI MOHD YASIN ID NUMBER: 0909B68332 PROGRAM: MECHANICAL ENGINEERING ACADEMIC SUPERVISOR: SOFIA ADILAH BASAR INDUSTRIAL SUPERVISOR: SEE SOO TECK DATE OF SUBMISSION: 16th MARCH 2012

CONTENT
Abstract 3 4

Acknowledgement Introduction 5

Assignment and trainings Tasks and assignments 8 Technical knowledge 11 Application of theory 16 Knowledge of company structure and procedure 18 Knowledge of function of other department 22 Recommended for improvements 24 Conclusion 25 References Appendix 26 27

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Abstract
Industrial training is one of the courses that need to be experience by engineering student in order to expose the students to the real tasks of an engineer. A lot of trainings, tasks and assignments were done in order to learn the skills, ethics, theories, and work procedures applied during working as an engineer. All the experiences also are very useful for engineering students in order to understand the responsibility and the real nature of engineers job. Not only that, an engineer also needs to aware about the company structure, work flow and policies. This will make a professional engineer with the best attitude and full of respect. Lastly, this industrial training is training the engineering students on how to bring improvements, innovations, new ideas or changes for the better world besides preparing for coping with the fast emergence technology era nowadays.

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Acknowledgement
Alhamdulillah, thanks to Allah S.W.T the most merciful and the most compassionate for the guidance and knowledge bestowed upon me, for without it I would not have been able to come this far. I would like to thank to Haisan Resources Sdn. Bhd. especially Ms. Pearl Dickman, Head of Human Resource Department of Haisan Resources who willing to accept me and provide a place for me to do my industrial training. Next I would like to give a lot of thank you to my company supervisor, Mr. See Soo Teck, vice president of engineering department for his invaluable supervision, assistance, guidance and support to me during 12 weeks of my industrial training. Not forget to the mechanical engineer of Haisan Sdn. Bhd., Mr. Kavin Jayaram who also did help me a lot to learn especially about the technical knowledge of the refrigeration system. Also thank you to all the engineering department team for the friendly treatment, ideas and support regardless directly or indirectly. Lastly, thanks to all my family, friends, lecturers and all who were helped me directly or indirectly during the 12 weeks of my industrial training.

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Introduction
Haisan Resouces Sdn. Bhd. is a company that providing both product and services for temperature controlled-logistic, industrial refrigeration engineering and ice manufacturing. Engineering department is attaches to the industrial refrigeration engineering division. This company is also supplying a comprehensive range of supporting equipment for the industrial refrigeration which includes accessories, spare parts and reconditioned equipment [1].

Ice Plant/Machine Cold Room Equipments:

Compressor Contact Freezer Pressure Vessel Air Blast freezers Evaporative Condenser Instantaneous water chillers Ammonia, Valves & Controls Instant Quick Freezing (IQF) system

Haisan Resources Sdn. Bhd. is the company that expert in designing cold storage facilities, ice plant, and various integrated industrial refrigeration systems. They also specialized in industrial refrigeration controls and electronic monitoring systems. Other than that, they also provide service of sourcing and fabrication of refrigeration equipments and installation, testing and commissioning of

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refrigeration system and equipments. This company has been doing fabricationcontractor of industrial refrigeration equipments in Malaysia with more than 30 years of experience. Beside providing a complete range of value-added engineering and construction services catering for the industrial refrigeration equipments, they are also well-experienced in vessel salvaging and trading of ammonia refrigeration spare parts, new and reconditioned ammonia refrigeration equipments as well as rendering of repair and maintenance service for refrigeration equipment or system.

The job of engineer here is basically to plan, design, and build a refrigeration system based on the requirement from the client. The company such as frozen food company, fishery company, ice cream company, bread company and many more needs their own refrigerated room to store their product. The refrigerated room can be the cooler room, chiller room, instant freezing room etc same as our fridge at home which has different compartment that has different temperature range to store different type of food. The requirement and specification obtained from certain clients are also differs from other clients. Thus the engineer needs to design a refrigeration system customized to the particular client. After designing, approval from Jabatan Keselamatan dan Kesihatan Pekerja (JKKP) for pressure vessel used in their design is needed to ensure the safety of the design. The engineer also needs to supervise the progression of the project during the installation process of the refrigeration. Until the installation process completed, engineer also needs to do the commissioning process of the

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system which will be the most important time of a project. During commissioning, the whole system will be checked if there any leak, error, mistake or else. If there any problem, the system has to be stopped and rework needs to be done. This procedure will be repeated until there is no problem occurs to the system. Lastly, hand-in certificate will be given to the client together with the manual on how to handle each machine and ammonia substance of the system.

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Assignments and trainings

Tasks and Assignments Along the 12 weeks of training, I have been given a lot of opportunity to do some tasks and assignments. At the beginning, some guidance, instruction and demonstration were provided to me. After that, I was given a chance to complete the tasks and assignments by myself.

One of the tasks that completed by me is, preparing the manual booklet for refrigeration system. This manual needs to be provided to client, together with the hand-over certificate. This manual contained, the a. b. c. d. Hand-over Certificate - Obtain from the project manager of the project. Schematic Drawing - Obtain from the draughtswoman Electrical circuit drawing - Also obtain from the draughtswoman JKKP Approvals for pressure vessel - Asked from Engineering Plant Manager/project coordinator. e. Instruction for working with ammonia - Search in the companys document based on the type of refrigerant f. User manual for the equipment. ( tube ice machine, compressor, condenser) - Search in the companys document based on the type and model of the equipments g. Catalogs for equipments Asked from the senior admin/purchasing executive.

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h.

How to operate the refrigeration system Obtain from mechanical

engineer or search in the companys document based on the type of compressor used. i. Based on the tasks above, I was able to understand the relation between the works of the engineer with the works of person that has different position in the company. This has thought me that we have to work in a team. Otherwise, the project will not going to run smoothly. In order to work as a team, meeting is an important communication channel. All updates and information need to be present and share with all team members that involve in the project during the meeting. Meeting also is an important place to make decision since all the problem and possible solution are speak out during the meeting. With the present of all the team members, each member can help one another and all the idea can be gathered. This shows the importance of team work in handling a project.

The other task is drawing. Since I had learned how to use Auto-CAD during my 1st year of engineering, it is an advantage for me in the company. I had a chance to do schematic and plant layout drawing for a few projects. Provided with all the dimensions, I was able to produce a drawing checked and approved by the project manager. Picture 1 below is one of the example of the drawing that adjusted by me for a minor tube ice machine project.

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Picture 1. I had learned on how to do the quotation for the project. The project costing and the list of equipment were obtained from the project coordinator. For the bigger cost project, the list of equipment is prepared together with the description of the equipment, term of payment, and the duration of delivery. Other than that, I also had a chance to observe how the engineer negotiates the price with the customers. Besides presenting the refrigeration system designed by engineer, the engineer also needs to have skill to offer a price to the customer. Some regular customers were given discounts and some customers were offered with extra refrigeration accessories. Here, I can see the multidisciplinary nature of the job of the engineer which also need play a role as marketing executive indirectly.

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Technical knowledge Working as engineer at Haisan Resources, one of the the technical

knowledge that engineer needs to expert is the mechanism and the parts of the compressor. In the whole refrigeration system, compressor is the most important and critical part. Haisan has a collection of books and catalogues of compressor for their references. Based on their collection, a lot of mechanisms of the compressor need to be understood in order to work with industrial refrigeration system. From the reading, there are 2 common types of compressor which are reciprocal (piston) and screw compressor. Picture 2 shows the cross section of the reciprocal compressor and picture 3 shows the inner part or screw compressor.

[2]

Picture 2

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[3]

Picture 3 Besides that, compressor which the most important equipment in the refrigeration system is always comes along with a few accessories. Some of the accessories are motor, oil separator, oil filter, accumulator, air purger and more. All these part is functions differently in order to support and to ensure the compressor run smoothly. Motor is a must for every compressor. Only a certain very large refrigeration systems are using hot water vapor to rotate the shaft. Oil separator is use to separate the oil used for lubricate with the refrigerant. The temperature of the oil needs to be checked regularly to ensure the temperature not is too high. If it is too high, the oil will evaporates and metal parts in the compressor will have a direct contact with each other. This direct contact condition will damage the compressor. Thus oil is mixed with the refrigerant in the suction part of the compressor, however needs to be separated back after discharge from the compressor. The separated oil will channel back to the suction Page | 12

part of the compressor. The oil filter is used to make sure the oil is always clean without any dirt or sediment. This oil filter needs to checked and changed after a certain period of time.

Working with refrigeration system that always use ammonia as refrigerant makes all the engineering team had experience the smell of the ammonia. Ammonia has a hard, sharp smell that if inhale it too much will causing vomiting and ever worst lung damage. Ammonia is toxic and more dangerous than the HFC refrigerants, but serious improvements have been made, and the charge has been considerably reduced. The ammonia is kept in the machine room and does not create any problems in practical life. Todays political trend is to reduce the use of HFC gases, either by imposing taxes like in Norway, Denmark and Austria, or by stopping the production (CFC gases).[4] Ammonia is a natural refrigerant which does not have any impact on the environment and it will not be subject to taxation or price increases.[4] Ammonia is more efficient as a refrigerant because ammonia has a higher latent capability per pound compared to the same pound of other refrigerant such as freon. Other refrigeration like Freon can do the same refrigeration work; it just takes more of it. Not only is ammonia cheaper per pound it also cost less to operate an ammonia system because it relates to power use. Ammonia will do the same refrigerationt task but uses less horse power. This comes down to less power cost and lower plant operating costs. That's the real reason ammonia is used in large applications.

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If customers got problem with their refrigeration system, they will call the engineer who in-charge for it to fix it. As engineer, all the checking, fixing, changing, maintain, overhauling and replacing parts procedures need to be known by the engineer so that it will be easy to give an instruction to the technician who will do the hands-on tasks. Experiencing the procedure of changing the oil filter of the compressor at Ramly Food Processing had taught me the real procedure of handling the ammonia, to resemble and to assemble the compressor parts. Changing procedure of oil filter of MYCOM Screw Compressor 1. The ammonia gas was discharged from compressor and oil separator into the water. Some of the ammonia gas was mixed together with oil thus, the ammonia needs to be discharged into water. 2. 3. 4. 5. 6. 7. 8. 9. 10. The remaining oil in the oil filter is removed. The cover of the oil filter is opened to remove the filter. The oil filter is removed from its case. The case of the oil filter is cleaned. All the dirt is removed. The case is checked whether it is clean enough or not. The new filter is put into the oil filter case. The case of the oil filter is closed with its cover. All the nuts were tightening. The compressor is run and checked whether the pressure difference of the oil filter is back to normal or not. After running, the compressor takes about 15 minutes to fully upload. The reading can be checked after the compressor if fully uploaded.

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*for more detail about the procedure, see appendix 1.

The other technical knowledge is how to manufacture the block ice machine. The concept is the same as the other refrigeration system; the difference is refrigeration system for block ice machine is cooling the brine water until the temperature below the freezing point of water. A hundreds of tanks filled with distilled water will submerged into the brine water because the freezing point of brine water (salt water) is lower that freezing point of pure water. Additional process needs to be added if want to produce clear block ice for the decoration purposes. The additional process is bubbling process. This process needs to be take place while the water is starts to freeze. Basically, normal block ice takes 2 day to fully freeze and clear block ice takes 6 days to freeze. For the clear picture about the block ice manufacturing, refer to the appendix 2.

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Application of theory All refrigeration system is applying the same concept. Same as the system

that applied by Haisans Industrial Refrigeration Engineering. This refrigeration knowledge is learnt during my 1st year 2nd semester at the engineering school in subject Thermodynamics and Heat Transfer. Diagram 1 shows the basic cycle of the refrigeration.

[5]]

Diagram 1 The most important stage of the refrigeration cycle is the compression stage. At this stage, the refrigerant (usually ammonia) will be compressed to smaller volume. This process is used to increase the pressure and temperature of the ammonia gas so that the compressed ammonia gas will easily change into Page | 16

liquid through the condenser. In this condenser, the state of the ammonia gas will change into liquid, however, and the pressure and temperature is still high. The pressure and temperature will go down through the next stage which pressure vessel. The pressure vessel will reduce the pressure and the temperature of the refrigerant liquid so that it will easily absorb heat and change its state back to gas. The gas again being compressed in the compressor and the process is repeated again and again. The major calculation part is the efficiency and capacity of the compressor. The engineer use particular software provided by the compressor supplier to calculate efficiency and capacity of the compressor. Thus, different brand of compressor need to be calculated using different type of software. Every compressor has its capacity limit which needs to be considered during designing the refrigeration system for the customer.

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 i.

Knowledge of company structure and procedures Corporate Structure of Haisan Resources Berhad

[6]

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ii.

Organisation Chart for Engineering Department of Haisan Resources Sdn. Bhd.

Vice President

Senior Admin/ Purchasing Executive

Engineering Plant Manager

Engineering & Servicing Technical Manager

Executive Marketing/ Mechanical Engineer

Executive, Draughtswoman / Project Coordinator

Store Supervisor

Fabrication Superintendent

Technical Supervisor

Supervisor

Assistant Supervisor

Fitter/ Welder

Junior Technical

As shown it the chart above, the organization is directs the vice president of the company. The vice president is assist by the senior admin who also work as purchasing executive. Going down the chart, there are 4 divisions. The first division is Engineering Plant Manager which manages, supply, orders the stock of

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the refrigeration machines and spare parts. Not only that, this division also incharge for the fabrication process of the refrigeration compartment such as condenser, liquid receiver, evaporators, etc. This compartment is made upon receiving the order from customers. This division has about 13-15 number of fitters and welders. The second is Engineering Servicing and Technical Manager which supply the human resources for servicing works (installing, repairing, commissioning, overhauling, maintaining, etc). This division also managing the servicing/maintaining schedule for the client so that the maintaining process of the refrigeration system is done to ensure it runs smoothly. This division has 6 workers. The technical supervisor and his assistant are the senior technicians; and 4 junior technicians ready to take action. The next division is the position of the mechanical engineer who is the designer of the refrigeration system required by the client. Mechanical engineer also deals directly to the customers and play a role as marketing executive of the company. Usually, mechanical engineer works with draughswoman/project coordinator to deal with customer on the cost, the duration of the project, the specification of the project, etc. The draughswoman, who also play a role as project coordinator is the person who will the managing, plan the project, do the gantt chart, do the project costing and etc together with the engineer. For Haisan Sdn. Bhd this last division will provide all the information needed by the client such as quotation, manual of the refrigeration system, schematic drawing of the system, hand-over certificate, etc. By knowing and respecting the other person of other position in the company will make the engineer more professional since professionalism is important in the work place.

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iii.

Work procedure of a refrigeration project Customer request for quotation Negotiation no accepted Customers purchase order and sign the quotation Customer request for new quotation

Plan the gantt chart

Prepare the bill of material (BOM) Stock availability? yes Pre-approved price list Fabrication no Purchase order

Schematic drawing (final) Testing, ok? yes Packing List

no

Delivery order

Loading & arranging Installation of equipment Equipment installation, civil and electrical work no Commissioning, ok? yes Hand-over Certificate Page | 21

Rework

Knowledge of function of other departments Even Haisan Company is made of 11 small companies; they are handled

by only one Human Resources Department. Source from the Assistant of the Head of Human Resources, Ms. NurSyeren, Haisan has about 400 staffs including the technical staffs for all 11 small companies. Some of the function and scope of work of human resources department are: i) Recruiting - Any department that needs workers will inform it to the HR department. HR department will take initiative to recruit the new workers for the particular department. ii) Interviewing - After recruiting, all the candidates will be interview by both, HR department and the department that needs the worker. During this stage, the qualified candidates will receive an offer letter from the company. iii) Orientating - After selecting the worker, the HR department will arrange for the orientation of the new workers. (Introduction to the company, introduction to the other staff, introduction to the work culture, introduction to the general info about the company) iv) Training - At this stage, the respective department will take responsibility to train the new workers. v) Payroll - HR department is the one who will in charge for the payment of the workers for every month. (payment slip, bank-in, producing cheque, overtime payment, etc)

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vi)

Arrangement of the staffs - If there any promotion or changing of department, HR department will manage all the process. ( updating data of the respective workers, inform to the manager, etc)

Besides human resources department, administration department also is one of the important departments for the worker. For Administration, they are incharge of the stationery, paper work, managing the filing system, leave application and MCs and so on. Since Haisan Resources is made up of 11 small companies, each the companies have different administration process. These processes are used to decrease the reliability of 1 company on others. If 1 company has problem on its administration, it will not affecting on the others. Thus, all companies can be run on its own. However, they have to add more workers to for their administration department. This will increase the cost of the workers of the company. For a well established company like Haisan, they have no problem to do it this way plus, this is a way for the company to reduce the stress of the workers by reducing the work load for each worker.

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Recommended for Improvements

Identification of areas of improvement Every company will have their own weakness. Haisan Reources is full of well experienced workers. However, most of their expertise are about to retire or leaving to another place. All these expertise do not have someone to replace them. Moreover, with only a few numbers of engineers seems not enough since the demand for the industrial refrigeration is getting higher. It can be seen on their organization chart which some staff is playing two roles in the company and doing multi tasking work due to the small number of workers. Some workers need to work overtime and carry a lot of workload at one time. This makes them very busy.

Proposal and recommendation for improvement For the problem above, Haisan needs to recruits and trains the new work

force. Even it is requires cost and time consume to train the new workers, its will worth it because the already expert workers are very hard to find. Another option is Haisan needs to do more activities for the company in order to appreciate the hard work of their workers so that their workers will not leave to another place. However, this suggestion has been rejected because they do not have time to train and guide the new workers.

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Conclusion
This industrial training course had opened my mind and eyes to the real nature of the work of an engineer. A lot of additional soft skills such as communication professionalism, punctuality, responsibility and other good attitude need to be acquired by engineering student in order to be a successful engineer. Those soft skills can not be learned in the class room; however it needs to develop through the experiences and exposure to the real work environment. Other than that, this industrial training experience gives engineering student a clear view of the work scope of an engineer. There is actually very wide work scope of engineer thus; they are carrying a large responsibility for the society. Not only that, an engineers also need to know about the function of other department because that will makes a versatile engineer. Understanding the engineering theory is only a part of it. If engineering students do not have the addition skill mentioned above, they will be just another typical engineer.

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References
1. 2. http://www.haisan.com/?page_id=232 http://knowledgepublications.com/doe/doe_mechanical_science_web_ educational_textbook_solar_hydrogen_fuel_cells.htm 3. 4. http://www.jagweb.com/aj6eng/supercharging_article.php Henrik Kudsk, Sabroe Refrigeration, Why is ammonia chiller more efficient? 5. 6. http://en.wikipedia.org/wiki/Refrigeration http://www.haisan.com/?page_id=219

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Appendices

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