Table of ContentsABSTRACT3CHAPTER 1: BACKGROUND OF THE COMPANY41.1.Syarikat Air Johor Holdings SDN BHD41.2.Company Historical Background41.3.Company Logo Organisation51.4.Vision51.5.Mission51.6.Background of Sultan Iskandar Water Treatment Plant61.6.1.Overview of Sultan Iskandar Water Treatment Plant (WTP)61.6.2.The WTP Operation71.6.3.The Source of the Raw Water81.7.Organization Chart91.7.1.Organization Chart-Production Department91.7.2.Organization Chart for Mechanical and Electrical Department :10CHAPTER 2: TRAINING PROVIDED TO STUDENTS IN GENERAL112.1.Industrial Intern Student Placement In Department112.1.1.Production Department112.1.2.Mechanical And Electrical Department142.2.Safety Equipment14CHAPTER 3: PROJECTS / TASKS GIVEN173.1.Given Tasks173.2.Given Project173.2.1.Project Overview173.2.1.1.The block diagram of project193.2.1.2.Schematic Diagram203.2.1.3.Ladder Diagram22CHAPTER 4: PROBLEM FACED234.1.The Shortest Of Internship Period234.2.Failure of Backwash Operation on Filter Tank23CHAPTER 5: CONCLUSION OF THE TRAINING PROVIDED25CHAPTER 6: RECOMMENDATIONS FOR IMPROVEMENT26References28Appendixes29

ABSTRACT

In the technical section, I was given daily task. The daily task is based on the works that company is doing. The place and job is depending on the progress. The task needs me to accomplish the assignment given by the supervisor. My task is doing some PLC ladder diagram based on the operation of the system. Other that, they give task to follow up the preventative maintenance works do by panel contractor. By doing all this, the trainee gain knowledge and experience from all this tasks.The company of Syarikat Air Johor Holding Sdn Bhd. was focus on specializing in water treatment and distribution of treated water to consumers (domestic, commercial and institutional customers). The scope activities of the company are Collect and retain from the customers charges and fees relating to the supply of treated water for different classes of consumers, Operations, maintenance and development of water treatment, reticulation and supporting systems.The industrial training report consists of the adaptation with the working place environment such as how to have attitude of punctuality, responsibility and teamwork. Beside that the occupational safety and health should be consider mostly during working at the work site, the safety equipment should be applied. The main content of the report was industrial experiences which is include the experiences of basic skill of technical staff mostly during working at site project, secondly the experiences involve was application skill of engineer which is more on applying the knowledge of engineering study.

CHAPTER 1: BACKGROUND OF THE COMPANY

1.1. Syarikat Air Johor Holdings SDN BHD

Syarikat Air Johor Holdings Sdn. Bhd. (SAJ) is the sole company that distributes water throughout Johor. It main business is supplying water to the consumers in Johor. Apart from that, it also plays an important role in educating consumers to avoid wasting water. Quality of treated water that had been supplied to the consumers is assured and obeyed the guidelines from Ministry of Health.

1. 1.1. 1.2. Company Historical Background

The summary history SAJ that went through some important events, which is:

YearsEvents

1989 JabatanKerja Raya Bekalan Air

January 1989JabatanBekalan Air Johor

February 1994 Syarikat Air Johor SdnBhd

March 2000

SAJ Holdings SdnBhd(Subsidiaries of Ranhill Utilities Company)SAJ Holdings SdnBhd

March 2009

(Restructuring of Johor Water Supply, migration)

March 2011

SAJ Holdings SdnBhd(Introduction of new logo)

Table 1.1 -The Chronology

1.3. Company Logo Organisation

1.4. Vision

To become a world class water utility company.

1.5. Mission

We shall continuously satisfy our customers and stakeholders by optimizing available resources and delivering quality services.

1.6. Background of Sultan Iskandar Water Treatment Plant

PLANT 1PLANT 2CHEMICAL BUILDINGCHLORINE BUILDINGTREATED WATER PUMPING HOUSEFigure 1.1: View from top of Sultan Iskandar Water Treatment Plant (SIWTP)

1.6.1. Overview of Sultan Iskandar Water Treatment Plant (WTP)

Sultan Iskandar WTP is located about 35km from Johor Bahru town , the WTP stage 1 begins operation in 1986 with designed capacity of 181.8 MLD . The stage 2 works started in 1994 involved the extension of treatment plant capacity from 181.8 MLD to 318.2 MLD which is equivalent to 318 000 m3/day to satisfy the increasing water demand in Johor Bahru district. The WTP covers supply areas of part of Pasir Gudang , Johor Bahru district and environ. Total area of WTP is 7.6 hectares and contains many important components for treatment processes of raw water. The administration building has the main control room (MCR) to monitor and control the whole processes of water treatment. Apart from that, M&E office also located in administration building to give technical support for this plant. so that it can runs efficiently.

1.6.2. The WTP Operation

Sultan Iskandar WTP operates 24x7 (24 hours a day , 7 days a week) and operated by total of 12 personnel. Working in shifts, each shift will be under supervision of 3 technicians and 1 plant superintendent. There are 3 shifts everyday with 3 plants operator on-duty at each shift. The Sungai Layang WTP is operated by one plant superintendent, 3 plant technicians, 12 plant operators, one clerk, one laboratory assistant and 2 crews. Operation of the water treatment process is usually controlled by the Main Control Room (MCR) through the Supervisory Control and Data Acquisition (SCADA). SCADA is a control system that based on the computer systems that monitor and control industrial process. Almost all operating systems water treatment process is controlled and viewed via this system with the Topkapi software. For the M&E Department, leaded by one M&E superintendent, one works planner, one chargeman, 4 technicians, one clerk and one crew. Production Department held the responsibility throughout water treatment process within the plant. They control the intake of water, treatment process, chemical process and output volume to be distributed. For SIWTP, the Production Department is lead by Plant Superintendent, En. Mohd Zamri Bin Mahamad Saad. Meanwhile Mechanical and Electrical Department (M&E) is completing the function of SIWTP. M&E is lead by M&E Superintendent, En. Yusli Bin Abd Jalil. It consists of electrical, mechanical, instrument technician and clerk. All the mechanical and electrical related problems, maintenances and project are conducted by M&E.1.6.3. The Source of the Raw Water

Abstraction of the raw water from Sultan Iskandar Dam to treatment plant is carried out through a 0.5km long m.s pipe size of about 1600mm by gravity flow or for case of water level might be below 22.80m3. Raw water is pump from Upper and Lower Layang Dams at the intake point to the plant. After that, the raw water is then injected with chlorine (pre-chlorine) to oxidize out the ferum, manganese, dissolved iron and ammonia. Water catchment areas should be orderly monitoring and management in both quality and quantity to enhance the plant efficiency

1.7. Organization Chart

1.7.1. Organization Chart-Production Department

Plant Manager(Mohd Nizam Ahmad)

Plant Superintendent(Zamri Mahammad Saad)Plant Operator(Azman Bin Taib)Assistant Technician(Hilmy Bin Inam Kordi)Assistant Technician(Mohd Hurairah Bin Nasir)Assistant Technician(Ahmad Tahar Bin Daud)Plant Operator(Juffri Bin Buang)Plant Operator(Mohd Shahriel Bin Sulaiman)Technician(Mohd. Shabri Bin Edi)Technician(Idris Bin Othman)

Admin(Rusnah Binti Mohd Yusof)Plant Operator(Mohd Yusof Bin Mokhtar)Assistant Technician(Jumaat Bin Amat)Technician(Kamal Bin Kusmi)Laboratory Assistant(Azmi Bin Mohamad)Crew(Abd Latif Bin Saaban)Crew(Kapeli Bin Manaf)Figure 1.2: Organization Chart for Production DepartmentPlant Operator(Mohd Azmi Bin Manon)Plant operator(Khalid Bin Nan)Plant Operator(Mohd Najid Bin Mohamad)Plant Operator(Lokmanulhakim Bin Katemon)

1.7.2. Organization Chart for Mechanical and Electrical Department :

M&E Superintendent (Yusli Bin Abd Jalil)

Instrument Technician(Azrinazura Binti Awi) (Khairul Zamree Bin Mohd Arof)Crew (Mohd Hanafia Bin Hasan)Electrical Chargeman (Abdul Aziz Bin Mohamad) Clerk (Norazah bte)Works Planner (Md Kalid Bin Sukari)

Mechanical Technician (Mohd Jamil Riduan)(Mohd. Zaini Bin Kasah)

Figure 1.3: Organization Chart for M&E Department

CHAPTER 2: TRAINING PROVIDED TO STUDENTS IN GENERAL

1. 2. 2.1. Industrial Intern Student Placement In Department

2.1.1. Production Department

At production department, they focused on the process of water being treated. The process can be monitored and controlled from Main Control Room (MCR) through the Supervisory Control and Data Acquisition (SCADA). If the SCADA system breakdown, the plant still can be operate on semi-auto operation which it operate on the sequences of relays and timers. Every student who undergo industrial training at the SIWTP will be briefed regarding the process of water is treated in stages during first week on production department. The process are divided into 6 which it screening, aeration, coagulation/flocculation, sedimentation, filtration, disinfection/pH adjustment.

Figure 2.1 : General water treatment process.In screening process, the floating debris such as woods, leaves, aquatic plants and others are screened at the intake. After screening, the denser suspended matters are removed by allowing water to pass through chamber where it settles down to the bottom.Raw water pumped from the intake is mixed with air at the aerator. The aeration process provides oxygen from atmosphere for the oxidation of dissolved iron and manganese to their insoluble form thus enables their removal. The process also helps in the removal of taste and odour. Coagulants, usually alum, are added leading to the formation of microscopic particles in water. This is followed by gentle agitation causing small particles in the water to collide and combine to become bigger settleable flocs.The flocs are allowed to flow through the sedimentation tank as uniform as possible for long enough period for them to settle. The clarified water will be collected from the top.If the flocs are light, another process will apply. In this process minute air bubbles are introduced. The flocs will stick to the air bubbles and float to the top. The clarified water will be collected from the bottom. This process is called Dissolve Air Flotation.The settled water then goes through filters where the fine particles and bacteria are trapped. The clean water then goes to the clear water tank. The filters are backwashed regularly through a combination of agitation by air and water to ensure efficient operations.In the clear water tank, the water is disinfected to destroy microorganism still remain in water after filtration. Gaseous chlorine or chlorine compound are normally used for disinfections. The pH is adjusted using lime or soda ash.The Summary on the Water Treatment Process in Sungai Layang

2.1.2. Mechanical And Electrical Department

In the department of mechanical and electrical, they will provide student placement in industry training based on the courses taken at their institution.For student take the electronic courses, they will place under supervise of instrumentation technician. Meanwhile students who majored in electrical or mechanical, they will be placed under surveillance of electrical technician or mechanical technician.This department will monitor the works of maintenance and new installation projects. Such of maintenance works that need to be monitored are reservoir monitoring system, plant automated system, motor & pump for pump houses, semi-automated operation system, and any relating to the mechanical, electrical and instrumentation.

2.2. Safety EquipmentAll injured and accident will occurred anywhere mostly at the site. During site visit/inspection several precaution and safety equipment need to be consider. The safety equipment that needs to be preparing during working at the site construction are safety boot, safety helmet, gloves, and safety eyes glasses.Table below show the safety equipment together with the function during working at the site project.No.Safety EquipmentNameFunctions

1Safety BootUse to protect the foot from the nail, screw and sharpen tool fail down. These boots are water proof and fire proof properties.

2Safety HelmetUse for outdoor activities

3GlovesUse for prevent from hot material, electric shock, and avoid from chemical in doing work.

4HeadsetUse for prevent from high noise environment.

CHAPTER 3: PROJECTS / TASKS GIVEN

3.1. Given Tasks

Under the Mechanical and Electrical (M&E) department, they give some task to being solve that based on the system they have. But, mostly they taught the practical software and hardware part that involves in process of water treatment. In other words, the application of the theories that have been taught (e.g.: ladder diagrams, schematic diagram, pneumatic system, hydraulic system, wiring system). Other than that, M & E superintendent En Yusli Bin Abd Jalil instructed an intern student to follow technician by rotation shift a day. Each technician doing different types of task. Commonly they monitoring panel contractor do preventative maintenance (pm) and services.Equipments under the surveillance of M & E will undergo pm by appointed contractor panel. Pm works will be once in 3 to 12 months.

3.2. Given Project

3.2.1. Project OverviewOne project was given related semi-auto operation of pulsator clarifier stage. The project is about the relays and timers will run in sequences. The new system has been referenced by the automatic system runs by programmable logic control (plc). The pulsator clarifier system operation divided into two parts. First part is about flushing and suction (pulsator) process. Second part is desludging process. It start with flushing process of motor vacuum which the air supply valve is open meanwhile the water was through the process of coagulation/flocculation from mixing chamber continuously flowing enter to vacuum chamber. Then, air supply valve closed to allow the suction process runs and raise the water level inside the vacuum chamber. This process like the concept of using straw with an extra hole to drink water. When the water being drink use straw with extra hole without closed it, the water cannot be raise otherwise it will flush or maintain in equal level of glass. If the straw is closed (covered), the water can be slurp.In pulsator clarifier tank the water going through sedimentation process. The flocs are allowed to flow through the sedimentation tank as uniform as possible for long enough period for them to settle. The clarified water will be collected from the top. During the process of sedimentation, the second part of process is taking placed. The flocculation formed will be removed through the desludging valve. Every pulsator clarifier tank have 4 desludging valve. Valve 1 and valve 3 (1st set desludging) are simultaneously open and closed. It also happens for valve 2 and valve 4 (2nd set desludging). Time between 1st and 2nd set were been set.This semi-automated system will be modifying some of wiring from automated pulsator panel. The interruption of panel occurs on terminal relays (XR-OUT) to output terminals (X-OUT). The system not be disturbed by the plc even the plc still running. That because the connections of outputs from plc are cut-off.

X-out terminalThe relays are activating when the switch selector is selected to semi-auto but cannot be operate as long as not activated the start button.

3.2.1.1. The block diagram of project

InputOutputOutput TerminalProgramming Logic Control (PLC)Relay Terminal Block

Old block diagram

InputOutputNew block diagramOutput TerminalProgramming Logic Control (PLC)

New Relay Terminal BlockRelay Terminal Block

3.2.1.2. Schematic Diagram

3.2.1.3. Ladder Diagram

CHAPTER 4: PROBLEM FACED

1. 2. 3. 4. 4.1. The Shortest Of Internship Period

The period of 8 weeks that Electrical Faculty of University Technology MARA (UiTM) been given to us for undergo industry training was too short. It gives a problem for students to apply the internship. A lot of companies refused to accept the students to undergo industry training for them. Furthermore, the notice from faculty was too late for students to search the suitable company and the process of cover letter from university takes a lot of time. However, this is only a minor problem for students that cannot be a reason from not taking part in industry training which is compulsary for our course.In period of practical training at Syarikat Air Johor Holding Sdn. Bhd. has build up the positive qualities such as commitment, dedication and passion. Preventive maintenance includes the many different types of how to use a machine, on-site project and maintenace. There are much exposure of working enviroment given that gave us lots of experience in order to face the field of engineering after completing our studies.Unfortunately, the 8 weeks period of time given to us were not enough to explore the world of preventive maintenance in detail. Preventive Maintenance at this company is still in infancy that need a lot management work in order to strengthened the company. The incoming projects were to low than expected during the 8 weeks of our industry training. So, the technician cannot show or teach us either testing or using equipment.

4.2. Failure of Backwash Operation on Filter Tank

The problem comes from many aspects. Such as human factor,the environment, the failure of some mechanical or electrical part and mis-instruction received in Programmable Logic Control (PLC). It will cause the signal have mis-sequences process. If the hydraulic valve failed to operate, it will resulting the burst pipes. So, the hydraulic valve is checked eitheir it have problem with oil leakage or wiring. Another posiblity is the failure of solenoid valve mulfunction for opening the air valve. If the solenoid fail to functioning, the proceses of blowing the tank is not gonna happen. So, the solenoid valve should be replace. The mis-instruction received in PLC is the last result to be suspect. Because, rarely PLC operates incorrect. If PLC operates incorrect operation, we use software name Proficy Machine. We try to communicate with PLC and download the program and instruction they received. Then, we trace the unusual operation sequences.

CHAPTER 5: CONCLUSION OF THE TRAINING PROVIDED

After done my industrial training program I conclude that, there is not easy to work in industry either in theoretical or practical. In fact, with this training programme, I become more understand about the electronic, which it combines together from theoretical or practical. It is very important to make sure our self ready to learn new knowledge and make the chance to learn interesting. All the experienced gain is beneficial to the student either in their study or daily life.This industrial training also has given a better picture of the potential employer in engineering industry nowadays. Beside of the useful experienced gain by the student, this industrial training has also provided advantage to both the university and the company. For university, they will know from the companys feedback of what category of student that the industry needed in order for the student to be employed and university can take the necessary action to meet industry demand.Besides that, I also obtained new knowledge, skills and experience while completing my industrial training. To make sure I more understand about this scope of work, I received training and monitoring of work by the Syarikat Air Johor Holding Sdn.Bhd. staffs for a few weeks to understand about the equipment function and the way to perform it. This way it could make an easier way to done my task that had been given by the staff.I also have learn to be a good communicator while I do my work. I share my experience on work through this report. I hope the reader will feel excited the same way like me when they read this report. I enjoying my industrial training for 8 weeks there.

CHAPTER 6: RECOMMENDATIONS FOR IMPROVEMENT

Syarikat Air Johor Holding SDN BHD is a good place to gain the experiences. With conductive work environment it will help student to training here. This company also has affluent colleagues to sharing knowledge and experiences. That will make trainee happy to go to works. It is good because trainee can learn something new and different.I suggest other student to come here to undergo their industrial training because there is a lot of things they can learned here. All the knowledge that I learn during my study at collage I used it during my practical training program. My industrial training program really interesting because I get the expose to the real industry world than what I just learn at collage. During study time at collage I only can imagine about the process work in industry but now I can see the process flow in reality.For the suggestion to the company and to the department, Syarikat Air Johor Holding need to continue the intake of students for internships in their place, but the number of students shall be adequate to the number of workers who could assist. In the future, the company can be more specific on the aspects of the software because it is very important part in this system. Despite it is quite difficult and takes a long time to understand, it is worth to the company providing basic exposure to students. If the company concerned students make mistakes, supervisors need to be there and give guidance.For the recommendation, the company management should inform the trainee which company will be placed before registration, it important for a trainee make some preparation and study the background of the company such as scope of activity involve. Beside that the company management should prepare the training schedule for the trainee, it important to mention the trainee what task and scope of work that will be assigned.

References

1) http://www.saj.com.my/V2/Content.php?content_id=1

2) http://www.saj.com.my/V2/Content.php?menu_parent_id=2&content_id=27

3) http://www.saj.com.my/V2/Content.php?menu_parent_id=2&content_id=25

4) http://www.saj.com.my/V2/Content.php?content_id=33

Appendixes

Sultan Iskandar Water Treatment Plant

Admin office

Main Control Room (MCR)

Chemical Refrigerator at Labarotary

Raw water pH analyzer and turbidity analyzer

Mixing Chamber

Clarifier Tank

Operator changing chlorine drum

Manual Flushing of Lime pipe

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