BP CHEMICALS (M) SDN. BHD

12 JAN – 12 JUN INDUSTRIAL TRAINING

POLYTECHNIC KUCHING SARAWAK

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:

• To integrate theory with practice• To introduce students to work culture and industrial

practices• To give opportunity to students to work with

industrial practitioners• To expose students to potential employers• To acquaint the Polytechnic students with industry

and its programs• Implement Health Safety and Environment (HSE)

practices at workplace.• Practical ethical professional work culture.• Acquire skills in communication, management and

team-work.

INDIVIDUAL OBJECTIVE

The following are my objectives for having this industrial training:

• Expose to the new working environment• To gain knowledge and exposure on equipments

use in chemical plant • To learn the technical knowledge• To practically apply theoretical knowledge learned • To enhance my leadership• To improve my soft skills

Overview of BPCM

Overview of BPCM• Located 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 resins

• It 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.

• 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

BPCM

An aromatic acid

Physically - White - Crystalline powder - Looks like powdered sugar

Raw material; paraxylene (PX) - Colourless - Flammable liquid; sweet odour - Separated from a mixed xylene stream; from refining of petroleum

PRODUCT

PTA

Fiber for clothing and

home furnishing

Polyester film and tape

Industrial and high

performance fiber polyesterElectrical

insulation

adhesive

Food and drink container packaging

coating

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

Overview of BPCM-PTA Process (Oxidation)

SOLVENT

PARAXYLENE

CATALYST

FEED MIXING

AIR

CRYSTALLIZATIONPrecipitation from Solvent

OXIDATION REACTIONCRUDE TA

TO STORAGE

STEAM TUBE DRYERRemove moistureFILTRATION

Separation TA Solids & HAc

Overview of BPCM-PTA Process (Purification)

CRUDE TA

FEED SLURRY

PROCESSWATER

HYDROGEN

HYDROGENATIONREACTION

CRYSTALLIZATIONPrecipitation from Solvent

CENTRIFUGING & FILTRATION

Remove p-Toluics

STEAM TUBE DRYERRemove moisture

PURIFIED TATO STORAGE

Process Water

Crude TA

MAINTENANCEORGANIZATION

MAINTENANCE MANAGERMr. David Eng

SECRETARY Tengku Putri

PLANNER

I&E SUPRITEN

DANTMr. Lim Su

Seng

INSTRUMENT

& analyzer supervisorMr. Amran Damrun Rani

I & C TECHNICIAN

: Mr. Hakim: Mr Zulhijah: Mr. Solehuddin( contract )Mr. Asean ( Contract )Mr. Imran( Contract )

ELECTRICALsupervisorMr. Mohd Azmi Othman

SHIFT COMPETENT PERSONMr. MustaphaMr. BurhanMr. TanaMr. Saad

DAILY COMPETENT PERSON

Mr. MasriMr Wan RozmanMr Mubin ( contractor)E&I Trainee ISAM

I & E ENGINEER

Ms. RozaimahMr.Azmi Mohd NoorMr. Mohd Noor HamzahUTP Trainee Intan

MECHANICAL

POWER DISTRIBUTION OF BPCM• Step down ration from 132kV to 11kV

• 132kV 11 kV

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

Transformer Step down Supply to

TR1 132kV / 11kV BC 101 A

TR2 132kV / 11kV BC 101 B

TR3 132kV / 11kV Utilities/Plant

TR4 132kV / 11kV Utilities/Plant

EXPERIENCESELECTRICALS

• Servicing motor and breaker• Do 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 storage• Install electrical equipment. Ex: socket, grounding for

discharge• Greasing motor• Test run generator• Electrical safety in hazardous area• Electrical isolation

Instrument

• Do installation/calibration of pressure transmitter

• Metler Toledo Training- new sensor• Calibration of pressure switch

Electrical tools

• Cable detector• Power quality• Multi meter• Avo meter

• Tripping tools• Clamp meter• Cathodic protection tools

• Insulation tester

• Pipe bending

•Smart field communicator

•Hand pump

•Panel for breaker test

•Simulator circuit breaker

•Thermal overload test

•Tool box

•Non flammable contact cleaner

• switching protection clothes

•Infrared cam

ELECTRICAL INSTALLATION

• Our main consideration of installation electrical equipment is ‘safety issue’

• Ex: Current leakage, Overflow

Trainee Activities

Service Breaker and Motor

Working at panel motor control center

415V Circuit breaker and motorcontact

Current transformer

Thermal overload

Circuit breaker

Start &stop indication

light

Reset button

Contact service

Breaker test

Breaker test bypass

Breaker test in ON position

Jumper to breaker testing equipment

Step for Breaker service• Check all connection and cable sleeve• Phase inlet & outlet stab connectors• Neutral inlet outlet stab connectors• Aux contact• Earth contact• Contactor terminals• Timer terminal• Fuse terminals• Current transducer terminals• Terminals outgoing (compartment)• Check abnormality patended supports• Service contactor• Lubricant moving mechanism• Function test rack in test pos. limit switch

• Function test remote off selector switch• Function test overload relay• 500V megger at close position

RE,YE,BE,RN,YN,BN, RY,RB,YB• Resistance check at open and close position

6.6kV breaker

Breaker part repairing

11kV Breaker operatingRepair in progress

Example motor

INDUCTION MOTOR

ROTOR & WINDING

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

Generator test run

Procedure to start

3mW generator procedure

• Check air compressor• Check generator and engine room• Check battery panel• Check master control panel at substation• Check generator control panel• Check & record meter reading• Start more than one hour• Stop generator

Overview of generator

troubleshoot

• Wiring installation• Breaker failure cannot energized. • Vacuum cleaner ,one motor carbon brush

failure • Plug direct on line starter

Repair

• Welding set• Vacuum• Wring installation• Plug and socket

Special project

Replaced sport light port storage

VSD install cable

Soft starter install cable

Cathodic protection pipeline and tank storage

• Cathodic 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.

Example cathodic protection potential

Test point and cathodic panel

Aircond part

• Replace compressor ac 132kV substation

Instrument part

CalibrateInstall

training

instrument

• Calibrate pressure switch use SFC and hand pump transmitter

• Install transmitter analogue at shipping use for transmit pressure nitrogen gases to analogue meter.

• Training new pH sensor from metler toledo

calibration

ConclusionIndustrial training program in BPCM had given

opportunities to trainee to prepare himself as future E&I technician.

BPCM is one of the best company/ plant for trainee to have exposure on chemical production plant industry.

6 months period is the most suitable duration period for industrial training because it has enough time to

maximize the learning process.BPCM has a lot of employees who is willing to help to

make this industrial training program a success.

Thank You

• For all STAFF E&I MAINTENANCE Mr LIM SU SENG, Mr AZMEE, MR AZMI, Mr HARRIS, Mr MOHD NOOR, Mdm RUZAIMAH, Mr AMRAN, Mr HJ Masri, Mr Wan Rozman, Mr Mubin, Mr Mustapha, Mr Tana, Mr Burhani , Mr Saadudin, Mr Hj Hakim, Mr Zulhijah, Mr Asean, Mr Imran, Mr Soleh.

• Mentor,( Mr Wan Rozman, Mr Azmi and Mr Mubin).• CONTRACTOR ESPECIALLY WARGA HIKMAT (Mr MUBIN, Mr PAKYA, Mr HARITH, Mr ALI)• UTP TRAINEE INTAN