industrial training report 2015

INDUSTRIAL TRAINING REPORT 2015

NAME : MUHAMMAD ARIFF FATHI BIN MAWARDI( 2012632884)

PROGRAM : BACHELOR OF ENGINEERING (HONs) CHEMICAL AND PROCESS

COURSE : CHE690

CLASS : EH2217A

COMPANY : LINDE GROUP

DEPARTMENT : SAFETY HEALTH ENVIRONMENT AND QUALITY(SHEQ)

INDUSTRIAL : MS PANIMALAR BASKARAN

SUPERVISOR

LINDE MALAYSIA

ContentsACKNOWLEDGEMENT.............................................................................................3

ABSTRACT.................................................................................................................4

DISCLOSURE STATEMENT......................................................................................5

INTRODUCTION........................................................................................................6

CONTENT.................................................................................................................. 7

Company Background.............................................................................................7

Golden Rule.......................................................................................................10

Air Separation Units(ASU)....................................................................................11

INTRODUCTION................................................................................................11

PLANT DESIGN AND PROCESS FLOW............................................................11

SAFETY AND ENVIRONMENTAL IMPACT.......................................................11

LOCATION OF AIR SEPARATION UNIT...........................................................11

RAW MATERIAL................................................................................................13

PROCESS DIAGRAM.........................................................................................15

MINI PROJECT.........................................................................................................16

Safety data sheet class 2013................................................................................16

SHEQ booth exhibition.........................................................................................17

WEEKLY INTERNSHIP ACTIVITY...........................................................................19

WEEK 1................................................................................................................. 19

WEEK 2................................................................................................................. 20

WEEK 3................................................................................................................. 21

WEEK 4................................................................................................................. 22

WEEK 5................................................................................................................. 22

WEEK 6................................................................................................................. 23

MUHAMMAD ARIFF FATHI BIN MAWARDIDegree of Chemical and Process Engineering(HOns)

LINDE MALAYSIA

ACKNOWLEDGEMENT

In the name of Allah the most gracious and merciful. Infinite praise to Allah the creator for His thousand bless for me to finally complete this industrial training report. Massive thanks to Mr Chan Choon Bim, the head of SHEQ department for giving me this opportunity to do an internship program with Linde Malaysia. In my opinion it was an invaluable experience to be a part of SHEQ team and learn how the team ensure the safety management aspect but at the same time, achieving the company sales target. In addition, I can apply all my knowledge and study in safety courses to help providing useful idea in order to improve the safety aspect at the company.

Endless thanks and appreciation to my industrial supervisor or to be honest, my mentor during the training period, Ms Panimalar Baskaran for all her time and dedication prior to my training. Under her help and guidance, I manage to complete my industrial training with challenging working experience in real industry environment as a chemical engineer specifically in safety perspective.

Moreover, a special thank to our beloved coordinator, Madam Asdarina for her hardworking and advice to us in order to secure our training placement before and after the training. Last but not least, to my lovely parent, siblings, friends and not to forget all the Linde Malaysia staff for their support and encouragement. Without them I would not be able to finish my training successfully.


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ABSTRACT

This report is written to describe all the activity along my 10 weeks of industrial training. The activity involving my completion of mini projects assigned to me, training involvement, plants site visit and daily activity during the period. The focus will be more on my mini project which is Safety data sheet compliance and SHEQ booth exhibition. Objective and benefit of all the activities will be detailed down and discussed further in order to have a better understanding.


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DISCLOSURE STATEMENT

This is to declare that I have read the report and that the information enclosed is correct and contains no confidential information.

Company : Linde Malaysia

Industrial Supervisor’s Name : Panimalar Baskaran

Position : SHE Engineer

Signature :

Date :


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INTRODUCTION

Industrial Training is one of the requirements for the completion Degree of Chemical and Bioprocess Engineering, under the Faculty of Chemical Engineering, Universiti Teknologi MARA. These are the objectives of industrial training ;

- To communicate effectively with fellow workers and supervisors on issue related to project given

- To demonstrate organizational skills and team work to carry out project given

- To perform basic engineering practices or research activities, including technical writing and project management

- To demonstrate the creativity and innovation in solving problems related to real life project

- To demonstrate high level of integrity, ethical and accountability in engineering practices

The training was completed in 10 week time, beginning from 13 th July 2015 until 18th September 2015. I was accepted to done my training at Linde Malaysia and was attached to Safety Health Environment and Quality (SHEQ) Department, and reporting to Ms Panimalar Baskaran, a SHE engineer and officially my industrial supervisor.


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CONTENT

Company Background

The company begins the business in 1960 named Malayan Oxygen Limited. During that time, this new company supply gases to various industries in petrochemical, electronics, steel and high technology companies. In 1974, the company grows their business in welding by supplying the electrode for the welding parts. 5 years later Malayan Oxygen Limited merged with Far East Oxygen to form Malaysian Oxygen Berhad which then being a public listed company on the main board of Kuala Lumpur Stock Exchange (KLSE). In 1998, the company improves their business by established the customer service centre. 2 years later, Malaysian Oxygen Berhad acquired Nissan Industrial Oxygen, one of the company competitors during that time thus widen their influenced in the gas industry. Later on in 2007 The Linde Group bought AL’s shares in ALBOC Jersey and wholly owned on subsidiary of the company and changed the name to MOX-Linde. After celebrating the 50th anniversary year in Malaysia in 2010, the company then officially renamed to Linde Malaysia.


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Linde Malaysia has been the industrial gases market leader in Malaysia for the past 50 years. Throughout this period, Linde Malaysia has expanded its footprint throughout the nation with well established infrastructure to support diverse industries through supply and service reliability. With the most comprehensive gases product portfolio and direct sales network in the country, more than 20 sales centres and 60 plants nationwide, this company specialize in providing total gas solutions to a variety of industries. They manufacture and distribute industrial, specialty and medical gases, and provide a range of related services including the installation of gas equipment, pipelines and associated engineering services. In addition, they also supply packaged chemicals, and welding and consumables products.


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Organization Chart SHEQ Department

The portfolio of each position is slightly difference from one another but the SHEQ team actually is emphasizing the core of the company safety which is the golden rules. The Golden Rules are among the pillar of the company that are based on incidents and experiences in the company and also reflect legal and regulatory requirements that apply in many of the countries in which Linde operates. The Golden Rules reinforce those critical areas of our existing management system that present a high risk of serious injury or fatality if not followed. Therefore, they must be adhered to at all times by everyone. In addition, local regulations and other Linde specific requirements must also be applied. In general anything related to the safety and quality of the company, customer and environment will be SHEQ department concern.


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Golden RuleConsist of 8 major parts:

1. Personal ownership for safety // We will consistently demonstrate

personal ownership and accountability for safety through our actions

and behaviours.

2. Driving and vehicles // We will operate our vehicles safely and

responsibly at all times and use the safety equipment provided.

3. Permit to work // We will use the permit to work system where

necessary to ensure hazards and risks are understood and controlled.

4. Working at height // We will only work at height when the required

safety measures to prevent falls are in place.

5. Lifting operations // We will ensure lifting operations utilising cranes

or other lifting devices are carried out safely.

6. Contractor management // We will select and manage our contractors

so that they meet The Linde Group’s safety requirements.

7. Engineering management of change // We will only proceed with

technical changes to process plants and process equipment when an

engineering management of change process addressing the safety risks

has been completed.

8. Incident reporting // We will report and investigate incidents so that

the causes can be identified and corrected, and learning shared.


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Air Separation Units(ASU)

INTRODUCTIONAir separation can be classified into 2 types;

i. Cryogenic air separation unit

A cryogenic air separation unit (ASU) is a process plant in which air is separated into component gases by distillation at low temperatures. The plant comprises an assembly of distillation columns, heat exchangers, adsorbers, and supporting machinery for compression, expansion and control of gases and liquids. The component gases are sold and distributed to customers for a wide variety of industrial, medical and other specialist applications.

ii. Non-Cryogenic air separation unit

It is possible to separate air into oxygen or nitrogen without using low temperatures through the use of Pressure Swing Adsorption. Non-Cryogenic Systems are mainly used for small-scale production, typically less than 100 tonnes per day.

PLANT DESIGN AND PROCESS FLOWThe design of an air separation plant depends on the scale of operations and the nature of the products required from it. While basic principles are always the same, process cycles and flows for each plant can vary significantly. Linde tonnage air separation plants operate on a range of different process cycles. Plants are designed and engineered to meet specific customer requirements, in a range of plant capacities extending to production of over 2,300 tonnes per day of oxygen, with co-production of nitrogen and argon.

SAFETY AND ENVIRONMENTAL IMPACTOxygen is a hazardous material and mis-operation of an air separation plant can lead to large energy releases with hazards to personnel and equipment. Operation must always be in accordance with specified safe practice. The air separation process is intrinsically clean and does not generate undesirable side products. However, because it is energy intensive, it indirectly causes release of a significant quantity of greenhouse gases. Therefore it is important to operate a plant in the most efficient manner, both to minimise cost and reduce the impact on the environment. While the raw material is free, ASU plants are energy-intensive. For example, a unit making 2,000 tonnes per day of oxygen consumes around 30 megawatts (MW) of electricity. The plant’s main machinery (the air feed and product compressors) accounts for the major part of power consumption.


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LOCATION OF AIR SEPARATION UNITIndustrial gases are only transported over distances that are economically viable. Since these distances are limited by transport costs and the physical properties of the gases, production facilities are located close to the markets they serve. For higher value products (eg, argon, helium, speciality gases), it may be feasible to locate the plant some distance from the customer.

Typically, air separation sites are located close to large tonnage customers such as:

I. steelworksII. chemical works

III. petrochemical plantsIV. oil refineries, andV. smelters

so that the gas may be supplied directly to the customer by pipeline.


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RAW MATERIAL i. Feed air

The raw material for air separation is air from the atmosphere, called feed air on an air separation site.

ii. Main Component Air from the atmosphere is made up of a mixture of several gases. The main components are nitrogen, oxygen and argon, with other gases present in smaller quantities.Water vapour is also present in feed air. The water content of air varies considerably with local ambient conditions. This diagram shows the main components of dry air.

This table lists other typical components of feed air.

Component Volume (% of air)

Water vapour Varies with temperature, humidity and pressure (see note 2 below)

Carbon dioxide 0.035 (Concentration varies and can be as high as 0.1% near chemicalplants or power stations.)

Helium 0.005

Neon 0.0016

Krypton 0.0011Xenon 0.000008

Carbon monoxide Varies according to local conditions.

Sulphur dioxide Varies according to local conditions.


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Nitrogen dioxide Varies according to local conditions.

Hydrogen sulphide Varies according to local conditions.

Ammonia Varies according to local conditions.

Methane Varies according to local conditions.

Other hydrocarbons Varies according to local conditions.


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PROCESS DIAGRAMThe basic process for large scale air separation has remained unchanged for decades. In this process:

i. air is compressed, then purified by removing carbon dioxide and water vapour

ii. cooled to nearly its liquefaction temperature, and theniii. separated by fractional distillation into oxygen, nitrogen and argon products.

This diagram provides a very simplified overview of the air separation process. Each air separation plant has a different, much more complex version of this process. The function of each piece of equipment is then described. The warm equipment includes all of the equipment that operates at ambient temperature or above. The cold equipment is housed inside the cold box.


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MINI PROJECT

Safety data sheet class 2013i. Occupational Safety and Health (Classification, Packaging and Labelling of

Hazardous Chemicals) Regulations 1997 (CPL Regulations)

The above regulation is a mechanism to control the supply of hazardous chemicals to the workplaces in Malaysia and came into force on 15th April 1997. The regulation is comply to all the supplier which the "Supplier" is referring to a person who includes a formulator, a manufacturer, an importer or a distributor. Hazardous chemical is any chemical which possesses any of the following properties in Schedule I of the regulations: explosive, oxidising, extremely flammable, highly flammable, flammable, very toxic, toxic, corrosive, harmful, irritant, or if relevant information exists to indicate that the chemical is hazardous.

ii. The Occupational Safety and Health (Classification, Labelling and Safety Data Sheet of Hazardous Chemicals) Regulations 2013 (CLASS Regulations)

The Occupational Safety and Health (Classification, Labelling and Safety Data Sheet of Hazardous Chemicals) Regulations 2013 (known as CLASS Regulations) were gazetted on 11 October 2013 and officially introduced GHS into Malaysia. A manufacturer or importer is required to prepare an inventory of hazardous chemicals, imported or supplied in a quantity of 1 ton per year or above for each calendar year. Such an inventory shall be submitted to the Department of Occupational Safety and Health no later than 31 March in the following year. CLASS regulations also require chemical manufacturers, importers, formulators, and distributors to classify, label and package chemicals, and compile safety data sheets according to the Industry Code of Practice(ICOP) which is aligned with UN GHS Rev. 3.ensure suppliers of hazardous chemicals provide sufficient information on hazards of chemicals that they supply, so as to mitigate the risk of accidents happening in the workplace, thus providing a safe and healthy working environment and conditions. This new regulation then is replacing the previous 1997 regulations.


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Therefore, my task is to convert all the chemical product gases produce by Linde from old CPL regulations which is generated from Germany to this new CLASS regulations comply in Malaysia. In general, the SDS is divided into 3 classifications; Pure gases, Industrial Mixtures gases and Special gases. Approximately about 570 chemical gases produced by Linde Malaysia.


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SHEQ booth exhibitionSHEQ head of department Mr Chan Coon Bim has assigned me to manage a side event of CICM(Chemical Industrial Council Malaysia) responsible care run which is open up booth exhibition representing SHEQ department. This is due to high responsibility and concern of current alarming rate of road accident in Malaysia. Therefore the HOD took an initiatives to create safety awareness among the road user especially the motorcyclist which is the major contribution of the fatality accident statistics in order to reduce the figures. Thus my assignment is to prepare a booth exhibition regarding to road safety and also come up with an interesting games that create safety awareness at the same time. This task might differ and not really related to chemical engineering yet has several advantages on me especially building my soft skills and leadership, social networking, event management and critical thinking. In the nutshell, experienced me to become more flexible and open minded to tackle a new challenge.

Games:i. Show me the way

Game Objectives:

a. To assure that the motorcyclist obey the safety rules on the road.b. To ensure the motorcyclist to fully concentrate and stay focus during riding.c. This game clearly shows that without one of our sense we tend to involve in

accident


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ii. ½ Minutes Safety

Game Objectives:

a) To nurture safety attitudes and behaviors on the road by creating safe environment condition.

b) To create awareness on road safety during riding or driving.

c) To prove to motorcyclist those safety measures take less than one minute time.


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WEEKLY INTERNSHIP ACTIVITY

WEEK 113th July-15th July 2015

On the first day, I have joined Contractor Safety Pass Training by SHE Engineer Mr Dinesh Raj. The training is given to all contractors hired by Linde Malaysia which cover safety regulation regarding contractor’s job. All the potential hazard and risk have been described briefly for their guidelines. The training end with a test to qualified and ensure the contractors understanding. Besides that, I have been introduced to one of the incident reporting management website named Synergi. The Synergi can be used to lodge a report, analyse and review current and previous case investigation. There was a weekly short session which take about 5-10 minutes that must be joined by all the Linde Pinnacle staffs named ‘Take 5’. During the session, all the staff selected staff will be presenting about anything regarding to safety such as safety driving, safety walking, internet security and etc. Take 5 session discuss about what to do in case of elevator trapped and fire at the office.

Reading of the week:

i. Emergency response for Linde Hicom Plantii. The rules of work by Macleod

iii. Safety Data Sheet(latest review)iv. CIMAH report for Hicom Plant(Rev02,Nov13)v. CIMAH report for Perai Plant(2nd submission, Rev01,Aug13)


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WEEK 221st July-24th July 2015

During the 2nd week I have been given a desktop computer for me to complete any task assigned by industrial supervisor, head of department or other SHEQ staffs. I also got my 1st mini assignment which is Safety Data Sheet Class 2013. I have been assigned to convert the pure gases about 50 gases in one week. The take 5 session this week discuss about personal injury and what to do during natural disaster occurrence. In addition I have been provided with coverall and safety equipment for preparation for plant site visit. On the 24th of July, I have joined safety meeting at Linde Hicom ASU-ROC plant. Besides attended the meeting, I have been given a tour to the plant to overview the plant process specifically for air separation unit. I have also joined the plan working safety inspection and risk hazard assessment at the plant. The plant is a Remote Operating Center which referring to the plant capability to control other plants in other 13 countries online. The ROC are managed and controlled by process control engineers which cover all the regional east asia.


i. Process description for ASUii. Guideline to Globally Harmonized System

iii. ASU generaliv. ASU hazards and loss prevention


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WEEK 327th July-2nd August 2015

SHEQ department has a short Monday morning meeting named Huddle Meeting which in the meeting all the SHEQ staff including the trainee that updated the task done on previous week. The huddle meeting this week cover about ppe expiry, sds availability, security acces and etc. Furthermore, Ms Panimalar, SHE engineer (my industrial supervisor) has briefly describe the SHEQ department, job scope, contribution to the company sales and sharing session along her period becoming an environment engineer. I have also joined a safety meeting with Mr Andy Cook, HSE Head of regional about safety update globally and safety level and achievement in Malaysia. In addition, I have joined the safety meeting at Linde PJ Plant, the biggest cylinder fillings in RSE. Despite the safety meeting, plan working safety inspection, risk hazard assessment I have been given the chance to overview the cylinder fillings process at the plant with the plant manager there. Last but not least, I have joined the National Stock Count with all the Linde staffs in order to update the latest company assets specifically all the cylinders produced. This indirectly taught me the cylinder asset management.


i. Argon separation processii. Argon purification process

iii. Public transport safety and security for commutersiv. Global Safety Assesmentv. Golden Safety Rule

vi. Helium process operationvii. Feed gas supply system


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WEEK 43rd August-7th August2015

Huddle meeting update for in cab camera review, contractor behavior assessment and etc. Beside the completion of SDS pure gases, I have been assigned by Mr Mohsin Abd Karim, SHEQ Central Manager to create Synergi account for all Linde Malaysia staff across the country involving Sabah and Sarawak. In addition I have helped Ms Panimalar managing the solid scheduling waste of Calcium Hydroxide on eswiss website, an official Department Of Environment (DOE) website. Moreover, Sunway management collaboration with Jabatan Bomba Dan Penyelamat have organized fire fighting training. The training covered both theoretically and practically training as we experienced ourselves fight different types of fire in various situations.


i. Permit to workii. Remote operating center

iii. Auditing

WEEK 510th August-14th August 2015

For the week 5, the Huddle Monday meeting cover Corrective Action Reporting (CAR), Safety Implementation Plan (SIP) and etc. Joined Contractor Safety Training Management for 2nd time as the new Project Site Safety Officer, Mr Ashraf had recently joined the team for new Linde Plant in Geybeng, Pahang. Beside that I have helped SHE engineer, Mr Dinesh Raj creating the emergency response plan for pinnacle tower in case of emergency. Take 5 session discussed about safety at petro station. I also helped Ms Panimalar translating Lesson From Incident (LFI) involving 8 cases in 2015. The LFI is done to find out the root causes of the accident and a guideline to others in order to avoid the same incident happens again in the future. Mr Dinesh, SHE engineer had asked my help for CAR overdue involving tonnage & PGP for CAR consolidation. Assigned by Ms Panimalar to complete SDS for special gases.


i. Maintenance, inspection & condition monitoringii. CAR report


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iii. Materials and service managementiv. Supplier quality and safety performance


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WEEK 617th August-21st September

In this week, the Huddle meeting summarized about our company latest project located in Geybeng, Pahang. Ms Eliani, SHE specialize lead the meeting as Mr Chan is absence due to outstation. In the next day, I have joined General Induction training together with others 10 new Linde staffs with various background and origin including Sabah, Serawak, Sri Lanka and India. The training cover safety and quality induction, employee advantages on medical, work codes ethics, inspirational experience sharing session by the management and etc.


industrial training report 2015

Documents

training period

weeks of industrial

training involvement

training placement

safety aspect

safety courses

safety perspective

safety health environment