FACULTY OF CHEMICAL & NATURAL RESOURCES ENGINEERING

PARTIAL INTERNSHIP REPORT

COURSE : LATIHAN INDUSTRI

COURSE CODE : BKF4916

NAME : AHMAD SHAHROOM BIN MOHD SHAH

STUDENT NUMBER : KA11034

INTERNSHIP COMPANY : CEMENT INDUSTRIES SABAH SDN.BHD

INTERNSHIP YEAR : SESSION 2014/2015 SEMESTER II

PROGRAMME CODE : BKC

1.0 INTRODUCTION

This report is about activities that have been conducted during internship period

according to each section. In this company, students are assigned to multiple section such as

mill section, workshop and maintenance section, packing section, electrical section, store

section and lastly lab section. Each section play important role in Cement Industries Sabah.

Mill section is about production. In this section, students are able to identify the process

involve in cement manufacturing as well as major equipment involved in cement

manufacturing process. In workshop and maintenance section, students are able to get involve

in equipment maintenance during shut-down or emergency shut-down period. In packing

section, students are able to see how the cement is packed and delivered to customer. In

electrical section, students are able to identify electrical equipment involved during

inspection and maintenance process. In store section, students are able to identify the process

flow of purchasing process as well as stock calculation process. Lastly, in laboratory section,

students are able to identify procedure involved to determine the blain of the Portland

cement. In this report, I will only explain on mill and workshop section as both of them play

important role in Cement Industries Sabah Sdn. Bhd.

2.0 JOB DESCRIPTION

No. Section Person-In-Charge Duration Job title/ Outline

01. Mill Section Mr. Roy Chin (PE)

Mr.Dominic

Gunsalam (MF)

Mr. Ayub Yusof

(MF)

06/07/2015-

31/07/2015

(4 weeks)

i. Study the cement grinding

process in CIS, start from the

handling of raw material to

finish product.

ii. Identify major equipment

involve in cement production

in mill area by visiting mill

with foreman

02. Packing

Section

Abd. Pata Dompok

(PF)

Jali Matusin (PF)

03/08/2015-

07/08/2015

(1 week)

i. Study the process of

packing and cement

distribution in CIS

03. Workshop

Section

Mr. Joseph Sindoong

(Sr. ME)

Mr. Mohd Faizul

(WF)

10/08/2015-

14/08/2015

(1 week)

i. Study the function of

workshop section in CIS.

ii. Able to prepare work

instruction for one of the

activity in workshop.

iii. Able to prepare a simple

maintenance report.

04. Electrical

Section

Mr. Andrew Chang

(Sr. EE)

17-21/8/2015

(1 week)

i. Study the function of

workshop section in CIS

Mr. Asmirul Yandi

(EE)

ii. Able to prepare Work

Instruction for one of the

activity in electrical

05. Store Section Mr. Suhali Alip

(Sr.SK)

24-28/8/2015

(1 week)

i. Study the function of store

section in CIS.

ii. Able to know the

purchasing process, record

inventory.

iii. Able to prepare work

instruction for one of the

activity in store

06. Laboratory Mr. Alimat @ Anuar

Hj Salam (QAM)

Ms. Sza Sza Melissa

(Chemist)

Mr. Shamsul Aziz

(Lab Tech)

01-04/09/2015

(1 week)

i. Study the quality

requirement for cement

product produced by CIS

07. Safety,

Health &

Environment

Mr. Alimat @ Anuar

Hj Salam (QAM)

Mr. Voo Chee Yen

(Sr. SHO)

Mr. Dainiel Daipir

(SHO)

07-09/09/2015

(3 days)

i. Study the safety, Health

and Environmental

programme in CIS

ii. Able to identify the safety

and health hazard as well as

the environmental aspect

from the process or activities

in CIS.

3.0 PROJECT REPORT

Problem to be solved.

During internship period, there are some projects that I involved with. One of the projects is

maintenance project of bulk tanker Silo B. In this project, we are assigned to change the worn

out bucket, chain and sprocket of the bulk tanker. 1 senior mechanical engineer, 2 workshop

foreman, 6 general workers and 6 contractors involved in this project.

Equipment.

Some of the equipment involved during the maintenance is oxy cutter, arc welding, forklift,

chain block, liver block, 25 tan cranes, air gun/impact gun and monkey block.

Method and technique (work procedure).

The chain is cut by using oxy cutter in the bulk tanker.

Old chain is taken out from the bulk tanker by using rope and forklift.

Old chain is replaced with new chain.

The new chain will be pulled into the bulk tanker and the old chain will be pulled out of the

bulk tanker.

The bucket connected to the old chain will be cut off by using oxy cutter.

Old sprocket on top of the bulk tanker will be replaced with new sprocket.

The gearbox will be adjusted based on the tension of the chain.

After the new sprocket is installed, the top cover is placed back to its original position.

Old bucket will be placed on the chain once the chain fit into the gear.

Safety recommendation

During the maintenance, there are some recommendations that I would like to give in order to

prevent unwanted incident from happening. First, all workers must use proper protective

equipment correctly. Improper use of PPE will reduce the efficiency of the PPE itself.

Second, ensure that the equipment that we are working on is switch off. Third, ensure that all

obstruction in the workplace is cleared before maintenance. Lastly, ensure that all the

workers communicate efficiently to prevent miscommunication during maintenance.

4.0 Technical skills, General knowledge and professional skills developed.

There are many technical skills and general knowledge that I obtained during this internship

session especially from mill and workshop section. In this report, I will explain and elaborate

what I have obtained during my internship time.

1. Mill Section.

In mill section, I used to visit mill area every day with the foreman and general worker.

They sometimes share their experience working in mill. Some of them have worked for

20 years. One of the works that I do is air cyclone fan cleaning. The blade must be

cleaned every time the mill stops working because when the dust accumulates on the fan

blade, the cyclone will vibrate. The vibration level depends on the thickness of the dust.

The fan is cleaned by using compressed air.

I also obtained a very valuable lesson during mill session. There was an incident where

the compressor that used to pump cement into the silo breakdown. This is because the

compressor is forced to pump cement to a 42m tall silo whereby the compressor only able

to pump cement to a 25m tall silo. When the compressor is forced to do work over their

allowed limit, the compressor will break. Here are picture of the gearbox shaft

breakdown.

As we can see in the picture, the shaft broke down to half and the alignment of the shaft is

altered. This is the result of overworking the compressor. From this incident, I can say

that we must identify the limit of the equipment and machine before working with them.

2. Workshop Section.

In workshop section, I gained a lot of knowledge especially in welding. In CIS, they used

to have arc welding and gas welding. Both have different purpose. Mostly, they used arc

welding in maintenance. When welding, a welder need to identify the type of steel that

will be welded, the type of rod that will be used and the amount of power that need to be

supplied. A welded also needs to ensure that the earth wire is connected properly. Based

on experience from workshop welder, he said that when doing a welding work on

equipment that have many steel component such as bearing, we must make sure that the

earth is connected close to the welded area to prevent disturbance toward other

components. Picture below shows how the earth wire should be connected.

5.0 Values

During my internship, there are some values that I obtained that change my perspective

toward engineering career.

i. Communication

Good communication between workers will result to high achievement and good

working environment. This is because when we are working, we cannot work

alone. We must work with out co-worker in order to achieve the target of the

production. Bad communication will result to bad achievement. Workers will

blame each other for any problem that arise during production.

ii. Teamwork.

Teamwork is essential in engineering career. This is because without teamwork,

we cannot achieve anything if we work in an organization. Poor teamwork will

result to bad achievement and unsatisfied work. Hence, all worker must able to

work in a team in order to achieve better success.

iii. Humble.

As a student that will be an engineer, we will work with other people that might

not have as high qualification as us engineers. But bear in mind, those workers

might not have qualification as high as us but their experience based knowledge is

something that cannot be obtained through reading book. That is why we must

stay humble toward our co-worker and improve our knowledge by asking the old

worker about their working experience.

6.0 Career plan.

Internship in Cement Industries Sabah have equiped me with knowledge and experience

regarding cement production process. In future, I tend to enter cement production industries

based on what I have studied here. This is because nowadays, all building and development

require cement. By entering cement industries, it is safe to say that my career in cement

industries will be better compare to oil and gas industries. My plan for the future is to

increase my knowledge on cement manufacturing as well as developing my softskill to

become a better person.

7.0 Conclusion

Based on the above report, I can say that by doing internship in Cement Industries Sabah, I

have obtained many knowledge regarding engineering career as well as experience directly

how ti feels to work with other people. I also able to equip myself with knowledge and

experience on cement manufacturing process. By undergoing internship in this company, I

am able to experience other working field such as mechanical, electrical and maintenance

department. This will help me to increase my knowledge and prepare myself to be a better

person.

This is to confirm that I have read the report and that the information enclosed is correct

and contains no confidential information.

Company: _____________________

Supervisor’s name: ________________________

Supervisor’s signature: _____________________

Date: _________________________