Li Technical Report Syahinb04182002 5

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LI Technical Report-Syahin(B04182002 5)
Civil Engineering (infrastructure) (Universiti Teknologi MARA)
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UNIVERSITI TEKNIKAL MALAYSIA MELAKA

FACULTY OF MECHANICAL ENGINEERING
INDUSTRIAL TRAINING TECHNICAL REPORT
Name: Syahin bin Shaifuddin
Course: Bachelor of Mechanical Engineering
Year: 3
Training Period: 10 Weeks
Industry Name: Asia Honour Paper Sdn. Bhd.

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INDUSTRIAL TRAINING TECHNICAL REPORT
AT
ASIA NONOUR PAPER SDN. BHD.
Period of Training: 20 July 2020 – 25 September 2020
Submitted by:
SYAHIN BIN SHAIFUDDIN
This Technical Report for Industrial Training is submitted to
Faculty of Mechanical Engineering,
Universiti Teknikal Malaysia Melaka
In partial fulfillment for Bachelor of Mechanical Engineering
Faculty of Mechanical Engineering
University Teknikal Malaysia Melaka
(September 2020)

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ABSTRACT
This report describes my activities as long as I undergo industrial training at the
company's Asia Honour SDN BHD. The company runs single pulp mill and paper mill source
entirely from recycled paper.
In this report we also describe in detail the company and maintenance mechanical
department background, as well as activities conducted throughout the training period, the
problems faced and Comments and suggestions for the organization and the Universiti
Teknikal Malaysia Melaka.
Hopefully, information described will satisfy the readers at the same time beneficial to me
and the organization itself. In addition, it can give me guidance and strength in dealing with all
the problems I will face when I am in the environment of work. Insha Allah.

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ABSTRAK
Laporan ini menerangkan tentang aktiviti saya sepanjang saya menjalani latihan industri
di syarikat Asia Honour SDN BHD. Syarikat ini menjalankan penghasilan pulpa dan kertas
tunggal bersumberkan sepenuhnya daripada kertas yang dikitar semula.
Dalam laporan ini kami juga menerangkan secara terperinci latar belakang jabatan
mekanikal syarikat dan penyelenggaraan, serta aktiviti yang dilakukan sepanjang tempoh
latihan, masalah yang dihadapi dan Komen dan cadangan untuk organisasi dan Universiti
Teknikal Malaysia Melaka.
Mudah-mudahan, maklumat yang dijelaskan dapat memuaskan pembaca sekaligus
memberi manfaat kepada saya dan organisasi itu sendiri. Di samping itu, ia dapat memberi
saya panduan dan kekuatan dalam menangani semua masalah yang akan saya hadapi ketika
berada di persekitaran tempat kerja. Insya Allah.

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ACKNOWLEDGEMENT
First and foremost, I would like to take a deepest appreciation to my supervisor, Mr.
PREKASH AMALDASS, Mechanical Manager in Maintenance Mechanical Department for
his essential supervision, patience, motivation, enthusiasm, and immense knowledge towards
the completion of this training.
I would also like to express my deepest gratitude to my person in charge, Mr. TOH, Mr.
AMRAN, Mr. AZMAN and all technician in Maintenance Mechanical Department for their
assist in real industry job scope throughout during of this training.
Not to forget my beloved parents for all the support given throughout this training. I would
also like to thank all of my colleagues who supported me in writing and push me to strive
towards my goal.

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TABLE OF CONTENTS
ABSTRACT.................................................................................................................................... 4
ABSTRAK ..................................................................................................................................... 5
ACKNOWLEDGEMENT .................................................................................................................. 6
TABLE OF CONTENTS .................................................................................................................... 7
CHAPTER 1 ................................................................................................................................... 9
Introduction ............................................................................................................................. 9
Objective ............................................................................................................................... 10
Scope ..................................................................................................................................... 10
CHAPTER 2 ................................................................................................................................. 11
ASIA HONOUR PAPER Mission ................................................................................................ 11
Maintenance Department Mission Statement ......................................................................... 11
Company Core Value .............................................................................................................. 12
Company Background............................................................................................................. 13
Organization Chart ................................................................................................................. 15
Asia Honour Paper Product..................................................................................................... 15
Company Location .................................................................................................................. 16
CHAPTER 3 ................................................................................................................................. 17
Job Scope Training.................................................................................................................. 17
Personal Safety Equipment ..................................................................................................... 18
Daily Team Training Activities ................................................................................................. 20
Maintenance Department ............................................................................................................ 20
Daily Inspection ............................................................................................................................. 21
Repair Leuver Blade ...................................................................................................................... 22
Repair Bar Screen .......................................................................................................................... 23
Repair Defoamer Pump................................................................................................................. 24
Change Multi-stage Pump Gasket................................................................................................. 25
Change Air Jet Ventilator Coupling ............................................................................................... 26
Rollshop Team ....................................................................................................................... 29
Crane Inspection ........................................................................................................................... 33
Mist Runner................................................................................................................................... 34
Non-Destructive Test .................................................................................................................... 35
Roll Service (Install Spherical Roller Bearing)................................................................................ 37
2nd Shutdown ................................................................................................................................ 39
Workshop in Fabrication Team ............................................................................................... 41
Fabrication Process ....................................................................................................................... 42

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Welding Machine .......................................................................................................................... 44

Grinder .......................................................................................................................................... 46
Oxy-Fuel Cutter ............................................................................................................................. 49
CHAPTER 4 ................................................................................................................................. 51
Conclusion ............................................................................................................................. 51
Recommendation ................................................................................................................... 52
References ............................................................................................................................. 52

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CHAPTER 1
Introduction
Facing the rapid development of times with the advancements in various fields,
especially in the increasingly sophisticated technology and rapid development, it is necessary
that strong and competent human resources are needed by doing Industrial Training to be
familiar with real work environment.
Industrial training programme is a requirement for students to graduate with Bachelor of
Mechanical Engineering in UTeM. The objective of this programs is to expose the student to
the working environment. This is very important so that they will not having a culture shock
once they enter the industry. Besides, it also helps students to understand to application of the
theories that they learned in the university.
It also is to build a good communication skill with group of workers and learn proper
behaviour of corporate life in industrial sector. The students also will be able instilled with
good moral values such as responsibility, commitment and trustworthy during the training.

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Objective
• The objectives of this industrial training are mainly focusing to develop skills and give
a real working experience to final year students. Normally this industrial training period
have several objectives which is stated as below: To gain real work experiences in the
actual industry environment.
• To gain knowledge via working experience thus improving technical knowledge.
• To adapt with working environment and practice working efficiently.
• To work effectively as an individual and team members.
Scope
Basically for the scope of industrial training, I would like to focus on the work culture, work
environment, and training activity.
• The work culture that had been implemented in Asia Honour Paper Sdn Bhd.
• The work environment that had been implemented in Asia Honour Paper Sdn
Bhd.
• The training activity that has added the knowledge, experience and skill gained
in Asia Honour Paper Sdn Bhd.
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CHAPTER 2
ASIA HONOUR PAPER Mission
To achieve sustainable profitability through innovative, good-quality

and eco-friendly paper product valued by our stakeholders.
Maintenance Department Mission Statement
To maintain the machinery and equipment at optimum level for pulp and
paper production to achieve good quality, high productivity and low cost.
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Company Core Value
Figure 1 TOPICC Core Values
• We are aligned by our common purpose and work
together as a COMPLEMENTARY TEAM
• We take OWNERSHIP to achieve outstanding results
and seek value all times
• We develop our PEOPLE to grow with us
• WE act with INTERGRITY at all times
• We understand our CUSTOMER and deliver best value
to them
• We act with zero complacency and always strive for
CONTINOUS IMPROVEMENT
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Company Background
Figure 2 MNI Logo
Malaysian Newsprint Industries (MNI) produces newsprint from old newspapers
(ONP), old magazines (OMG) and telephone directories, which are 100% postconsumer
materials. The mill site is located in Mentakab, Malaysia.MNI is owned by three of Malaysia's
largest newspaper publishers, Hong Leong News Strait Times, Rimbunan Hijau Group, and
one of the world's largest newsprint producers, Fletcher Challenge. This makes MNI the largest
local supplier of newsprint with 70% of the market and provides MNI access to an international
base of newsprint manufacturing expertise.
MNI is the largest collector of old newspapers and old magazines in Malaysia. ONP and
OMG are MNI's prime raw materials, which until very recently were mostly disposed of in
landfills or sold offshore.The mill utilizes various known deinking and bleaching techniques to
produce a superior pulp without the use of chlorine. The mill processes 270,000 tons per year
of mixed waste to produce over 250,000 tons per year of newsprintThe mill receives and treats
up to 19 000 m day of water from the Sungai Pahang for use in the mill.The mill effluent will
be treated and returned to the river.
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Figure 3 AHP Logo Figure 4 RGE Logo
Late 2018, the company facing liquidation and Royal Golden Eagle Group (RGE) take
over this company. RGE was founded by SUKANTO TANOTO in 1973 as RGM. The assets
held by RGE companies today exceed US $20 billion. With more than 60,000 employees, we
have operations in Indonesia, China, Brazil, Spain and Canada, and continue to expand to
engage newer markets and communities. This paper mill name officially changed to Asia
Honour Paper Sdn. Bhd. (AHP). The production still operates the same, then new product and
project will be coming to produce A4 paper that known as Paper One a flagship brand.
While our core competencies lie in growing and harvesting trees, and energy resource
development, our companies across various sectors also produce and distribute a diverse range
of quality products. Our operations are driven by sustainable practices and development, to
achieve quality with energy and cost efficiency. We adopt industry best practices and intensive
research and development (R&D) to differentiate ourselves and maintain competitive
advantage. Our teams of international professionals and the use of cutting-edge technologies
remain key to our operations. We work towards establishing long-term mutually beneficial
relationships, characterised by our dedication to the community, economy via jobs creation,
skills upgrading and environment via sustainable practices and R&D. RGE group of companies
are involved in the following business segments: Pulp and Paper (APRIL and Asia Symbol),
Palm Oil (Asian Agri and Apical), Specialty Cellulose (Bracell), Viscose Fibre
(Sateri and Asia Pacific Rayon) and Integrated Energy Provider (Pacific Oil & Gas).
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Organization Chart
Asia Honour Paper Product
Recycled printing and writing paper that used in a variety of applications that include
books, magazines, commercial printing, copying and more.
Packaging paper material used to wrap and package goods. It has different grades and types
that include kraft paper and corrugated fibreboards.
Newsprint a low-cost paper commonly used in newspapers and other publications. It is
mostly made of wood pulp. Most newsprint today is made from recycled fibres.
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Company Location
Figure 5 AHP Maps
Asia Honour Paper Mill
Lot 3771, Temerloh Industrial Park, 28400 Mentakab, Pahang Darul Makmur, Malaysia.
Tel: +609 271 5100
Fax: +609 217 5115
Asia Honour Paper KL Office
Level 12, Wisma Averis (Tower 2) Avenue 5 Bangsar South City, No 8 Jalan Kerinchi 59200
Kuala Lumpur, Malaysia
Tel: +603 2785 7878
Fax: +603 2242 1420
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CHAPTER 3
Job Scope Training
In this chapter, details of the work culture, work environment that had been implemented
in Asia Honour Paper Sdn. Bhd. and the training activity that have be done for almost 10 weeks.
For work culture, basically Asia Honour Paper Sdn. Bhd always made safety come first which
is in the job scope of occupational safety and health. Furthermore, for work environment that
been implemented in Asia Honour Paper Sdn. Bhd was teamwork and work ethics. For training
activity, I have been attached on the Maintenance Mechanical Department of this Paper Mill.
In this team, it focused more on spare parts management.
During the flow of training, I was assigned under supervision of Mr.PREKASH
AMALDASS (Mechanical Manager). The scopes of training are to assist engineer and
technician in maintaining the paper mill, design and fabricate any part in helps the paper mill
operations goes well with safe and user friendly. During this 10 week of industrial training I
had been assigned to three team under Maintenance Mechanical Department. Maintenance
Mechanical Department consists too many teams that had been divided to them specific task.
For this internship I had been assigned to three team, that were ;
• Daily Team (week 1-2)
• Rollshop Team (week 3-7)
• Workshop as welder (week 8-9)
The training learned in this type of team very different and focussing just in job to be
completed. There is not much that we can learn since all the engineers and staffs were too busy
working on customer projects. All the knowledge learned are depending on the student
initiative.
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Personal Safety Equipment
Personal safety equipment (PSE) must have and be able to use the following personal
safety equipment whenever you enter the mill Some of these items are specifically required
for certain areas of the mill.
Item Description
Mandatory: Wear a hard hat in all areas of

the mill at all times until start up. After starts
up, hard hat areas will be determined.
Safety Helmet
Mandatory: Wear safety shoes at all times

in all areas of the mill as designated.
Safety Shoes
Mandatory: Wear hearing protection in all

areas of the mill outside of the control room.
Due to high frequency over 80db in long
time can cause hearing problem.
Ear Plug
A dust mask may be required in dusty areas

or when handling dry chemicals. Protect dust
and chemical enter the respiratory system or
it will cause respiratory diseases due to
hazardous chemical.
Mask
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Wear glove during do work in workshop to

protect hand from sharp tool and dirty oil.
Hand Gloves
Mandatory: Wear safety goggles when

working with certain chemicals or in dusty
areas
Goggles
Mandatory: Wear leather gloves when

doing hot work and cutting job especially
welding.
Leather Gloves
Safety glasses are required in designated

areas of the mill and workshop work. Prevent
flying particle during cutting entering the
eyes area.
Safety Glasses
Table 1 PSE List
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Daily Team Training Activities
During my first week training, I was placed under Mr. AMRAN the PM technician.
Basically, PM site is where the processed fibre formed, dried and rolled to result paper. By
following Mr. AMRAN, I’m a little bit know the structure and geometry of RCF and PM site
also the technician job scope.
Maintenance Department
Figure 6 Maintenance Meeting Space
In this department, cover up two site of paper mill which is Recycle Fibre Plant (RCF) and
Paper Machine (PM) to be maintained. RCF critical process, feeding the main paper machines
which produce more than 300,000 tonnes of newsprint per annum. Any stoppage on the RCF
affects the entire production.
During my first week training, I was placed under Mr. AMRAN the PM technician.
Basically, PM site is where the processed fibre formed, dried and rolled to result paper. By
following Mr. AMRAN, I’m a little bit know the structure and geometry of RCF and PM site
also the technician job scope.
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Daily Inspection
Figure 7 Paper Machine Checklist Figure 8 Handled Vibration Sensor
Every day in morning sessions, daily team will do inspection to all equipment that used
to operate the paper machine. The technician had to check all pump, motor, pipe etc. in the
checklist prepared and make sure it all runs in good condition without any abnormal sound,
leaks and high vibration. If there any critical leak or problem, the technician had to report
immediately to the maintenance team and follow up the procedure to solve it.
Figure 3 Vibration Sensor Details
In order to inspect the pump vibration, we used basic handheld vibration sensor to read the
pump and other bearing contained machine vibration and make sure the vibration not exceed
the maximum value. If the vibration over the maximum value, it may cause the pump
misalignment, increase the temperature of the pump due to high friction in bearing, shorten the
reliability of the bearing and result damaging the pump blade and other.
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Repair Leuver Blade
Leuver blade is a gravity-operated that combined louver design for exhausted air
applications.
Figure 9 Leuver Blade
Problem: The blades fall/detach from the frame due to soft material of blade that cause the
joint tear effect from vibration and dust weight.
Solution: Create new hole or re-bore the old hole and rivet the blade back to it frame.
Figure 10 Assembling Leuver Blade Process
Conclusion: Re-bore and new holes process make myself learn to use hand drill properly and
fit the blade to the frame using air-compressor rivet.
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Repair Bar Screen
Bar screen is one of water filter machine that function to segregate large trash before the
water flow out from the mill drainage system.
Figure 11 Damage Cable of Power supply

Problem: The bar screen machine does not work even the power still be supply.
Figure 12 Topping Lubrcant Oil Figure 13 Finish Repair

Solution: After checked the motor chain system there nothing blocked the bar screen from
rotate and the gearbox also not the caused the machine stopped. Then, call E&I to inspect the
motor there may possibilities of electrical problem of the motor. The problem founded that the
cable of electric supply to the motor damage. Solved just by rewrap the with tape.
Conclusion: I have learnt the correct procedure to solve a problem from checking the simple
possibilities to the bigger of problem. Also call the correct person to assists, if does not have
any expertise to solve it.

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Repair Defoamer Pump
This pump supply defoamer chemical to paper machine. Defoamer is a chemical additive
that reduces and hinders the formation of foam in industrial process liquids.
Problem: One of two defoamer pump does not function when the power turned on. The
chemical does not flow when the rotor rotates.
Figure 15 Stator of Defoamer Pump
Figure 14 Rotor of Defoamer Pump
Solution: The pump rotor stator has to de-assemble and inspected. It seems like wear but still
can be use. After bleeding have been done, the pump work normally.
Conclusions: Rotor pump is specialized for chemical. Proper manual handling due changed
to other motor need to be follow preventing the bubble trapping and disturb the chemical
flowrate of the defoamer.
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Change Multi-stage Pump Gasket
Multi-stage pump used to supply high water pressure for paper machine in cleaning, forming
etc of the paper.
Problem: One of the pumps had leak, it needs to be service to prevent the leak worsen and
effect the paper machine operation.
Figure 16 Multi-Stage Pump 70 bar
Figure 17 Leak Seal
Solution: The pump has to de-assemble and mechanical seal caused the pump leak detected
then need to be service.
Conclusions: Before performs this task, it need apply work permit to PIC at PM room and
isolate the pump properly to avoid any unintentional incidents happen. All the bearing and
internal part had to check wisely, whether it still can be reuse or not prevent any leak or other
problem from occur.
During tighten of the bearing housing, we found that the pump shaft hard to be rotate even
adding shim. Improper weld of lock washer caused it rubbing against the bearing housing.
After smoothed the welded part the problem solved.
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Change Air Jet Ventilator Coupling
Air ventilator very important during paper machine operating to make sure the paper dried
properly and quality of paper can be maintained.
Figure 19 Damaged Old Coupler
Figure 18 Stopping the Coupler Process

Problem: The motor producing high vibration and the rubber coupler worn out. The
surrounding heat and non-stop rotating fasten the coupler to worn out.
Figure 20 New Tire Coupler
Solution: New coupler need to be replaced to prevent major problem and stopped the fan from
rotating caused of break rubber coupler.
Conclusion: During the short shut, this coupler needs to be changed. The tool and new
coupler have been prepared. After applied the work permit and isolated the system, the
change process begins. Make sure and double check, all screw tight fitly caused this fan
rotated at high rpm and run for long duration
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1st Shutdown
Shutdown is a time when the paper machine and RCF plant stopped to be maintained in
a duration that has been fixed. Outside contractor has been deployed to assists in service, fix,
change etc. of problems under company’s technician supervision.
On Tuesday (3/8/20), I had involved in a shutdown of PM and RCF for 26hrs, I’m with
three others contract assigned to help Mr. AMRAN to complete the task given that had been
checked yesterday to make sure that task given were the correct problem and tools prepared.
Figure 21 RCF Plant Figure 22 Assigned Contract
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Change Filtrate pump 3 Bar
Problem: Suspected internal leak and bearing problem due to high vibration had been
reported.
Figure 23 Changing Pump Process
Solution: De-attached the pump body, bring to the workshop to be service. Use the old
impeller to the new body. Then, assemble back the body to it pump head.
Conclusion: Before de-attached the pump, work permit had to be applied and system need to
be isolate. To de-attach the pump body from it head, all the screw of the body and coupler
need to be removed. Then, the pump body lifted with 5 tons chain block. This process needs
to be done carefully to avoid the pump from fall and the impeller from broken.
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Rollshop Team
Figure 24 PM Lines
A team that given task to make sure all the roller in paper machine working efficiently and
good condition. There are four main sections on this paper machine. The forming section makes
the pulp into the basis of for sheets along the wire. Paper sheet formation begins immediately
when stock is fed from the headbox to the forming section of the paper machine, called the
Duo Former CFD. The Duo Former is a continuous twin-wire former, which means that the
paper sheet is formed as the dilute stock solution is pressed between two wires that are
travelling continuously at equal speeds around the former.The removal of water from the stock
during sheet formation occurs on the Duoformer The action of the vacuum rolls and wires on
the stock drains approximately 12% of the water from the stock, increasing the consistency
from 12% to 13%. Vacuum is applied to the rolls and wires to remove the water in a continuous
and well-controlled manner, ensuring that the properties of the paper sheet are consistent in
both the machine direction and ross direction.
The press section, which removes much of the remaining water via a system of nips
formed by rolls pressing against each other aided by press felts that support the sheet and absorb
the pressed water. The paper sheet is transferred from the forming wire to the pick-up felt by
the vacuum of the pick-up suction roll. The pick-up felt carries the sheet into the Ist press nip,
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where the low vacuum clamber in the suction press roll removes water from the sheet and holds
the sheet to the pick-up felt. The low vacuum chamber also draws steam into the paper sheet
to heat the sheet and enlance water removal in the 2nd press nip. The 1st press profile roll has
a grooved shell that allows removal of water pressed from the sheet. The paper sheet follows
the suction press roll into the 2nd press nip, which has a higher pressure than the 1st press nip
and forces more water out of the sheet Water is removed through the high vacuum chamber in
the suction press roll The high vacuum chamber is located at the front end of the 2nd press nip
therefore the sheet is released by the suction press roll after the 2nd press nip. The sheet follows
the center roll into the 3rd press nip, which is at a higher pressure than the 2nd press nip. The
3rd press profile roll has a grooved shell that allows removal of water pressed from the sheet.
The paper sheet continues to follow the center roll out of the 3rd press up, and the No i paper
roll directs the sheet to the 4th press felt. The 4th press suction roll applies vacuum to the sheet
and holds it onto the 4th press felt which cames the sheet into the 4th press nip, Water is
discharged through the grooves of the profile roll at the 4th press nip The No. 2 paper roll
guides the pressed sheet from 4th press nip to the dryer section. The four presses increase the
sheet dryness from 13% consistency to approximately 47% consistency.
The dryer section of the paper machine, as its name suggests, dries the paper by way of a
series of internally steam-heated cylinders that evaporate the moisture. The heat from the dryer
cylinders raises the temperature of the water trapped in the sheet This produces water vapor
that is given off by the sheet as it passes through the dryer. The sheet entering the calendar
stocks after dryer cylinder 36 has approximately 92% of its water removed. The 36 dryer
cylinders in the dryers are arranged into four steam groups, piped to a steam and condensate
system Steam is supplied to the dryer cylinders from four steam headers and condensate is
removed from the cylinders by the condensate headers. The steam enters the dryer cylinders
and heats them. The sheet is heated as it comes in contact with the cylinders. The heat causes
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the water in the sheet to evaporate As the steam loses its heat, it condenses in the dryer cylinders
to form condensate, which is removed through the condensate headers
Calenders are used to make the paper surface extra smooth and glossy. The calendering
and quality control system is an essential component of the paper manufacturing process. The
calendering process provides the final press and finish to the sheet leaving the dryer section.
The paper sheet produced must meet the quality specifications of the grade being nun Measured
variables (parameters) that determine sheet quality are basis weight, moisture content, caliper,
opacity, formation and brightness. The calender stacks enable the sheet to meet these
specifications by compacting the fibers in the sheet and controlling the sheet caliper and finish.
Figure 25 General PM Design
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Figure 26 Actual Forming and Press Section
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Crane Inspection
Crane is a type of machine, generally equipped with a hoist rope, wire ropes or chains,
and sheaves, that can be used both to lift and lower materials and to move or lifting heavy
things and transporting them to other places.
Figure 28 Crane Test

Figure 27 Lubrication Crane Cable
There was lots of crane in this mill, but some of them were under rollshop team supervision
were overhead crane. Wet & Dry end, Winder 1 & 2 were overhead crane that needs to be
properly checked and test prevent any disturbance during operation in paper production or
repair progress.
Winder 1 overhead crane need to be checked daily, the bolt used to hold the bridge idler
wheel always loose. The 3 bolts need tightening with a torque of 250Nm based on material and
size. If the bolt over tightens it will cause the bolt failure.
By changed the crane motor does not solve the problem, maybe this crane needs to be re-
alignment or service. For now, with crane inspection just to prevent the crane from worsening.
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Mist Runner
Mist Runner is a device that wax the dryer cylinder. It sprayed out anti-stick chemical like
wax on the dryer cylinder surface while it on running. To prevent any small particle, dust or
paper from stick at the dryer cylinder.
Figure 29 Pulled Out Mist Runner
Problem: The mist runner stopped work/jammed need to be pull out and inspect the motor and
nozzle if any block the nozzle hole.
Solution: Our task just needs to pull out the mist runner device out from the dryer line, it about
5 meter long. Overhead crane needs to hold the mist runner out and pull it nicely, prevent any
it from slip and hit other dryer cylinder and caused other problem.
Conclusion: To install the sling, we need to make sure the load and the centre of mass of the
device. It to prevent the sling break-up cause of over it limits and the long device tilt and swing
that may danger to people surrounding and slip out the mist runner track.
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Non-Destructive Test
Figure 30 Type NDT
Non-destructive testing (NDT) is a wide group of analysis techniques used in science and
technology industry to evaluate the properties of a material, component or system without
causing damage. NDT is used in a variety of settings that covers a wide range of industrial
activity, and routinely applied in industries where a failure of a component would cause
significant hazard or economic loss.
Method: Roll is an importance gear in paper machine to produce paper. It has to been check
properly in avoid problem when had to running for long term. Fluorescent liquid penetrant
testing is one of NDT method implement by Rollshop in service the rollers. A liquid with high
surface wetting characteristics is applied. excess liquid then removed from the surface of the
part. A developer (powder) is applied to pull the trapped penetrant out the defect. Last, the
inspection is done under UV light to increase test sensitivity.
Conclusion: NDT is one of method to save cost and less downtime. Since substances are not
altered by NDT, they can continue to be used. That means less wasted samples also using some
methods, the materials can be tested even while in use, which eliminates the need to shut down
operations during testing. Wearing PPE is a must protect yourself from the hazardous chemical.
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Figure 31 Shell Cleaning with Figure 32 Spray Fluorescent Liquid Figure 33 UV Light Process
Fresh water
Figure 34 Penetrant, Cleaner &

Developer
Figure 35 After apply Penetrant Figure 36 After apply Developer
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Roll Service (Install Spherical Roller Bearing)
A spherical roller bearing is a rolling-element bearing that permits rotation with low
friction, and permits angular misalignment. Typically these bearings support a rotating shaft in
the bore of the inner ring that may be misaligned in respect to the outer ring. The misalignment
is possible due to the spherical internal shape of the outer ring and spherical rollers. Despite
what their name may imply, spherical roller bearings are not truly spherical in shape. The
rolling elements of spherical roller bearings are mainly cylindrical in shape, but have a (barrel
like) profile that makes them appear like cylinders that have been slightly over-inflated
Method: After the double-row spherical roller bearing had been inspected with no sign of
failure such as deep scratch, noise, and loose. Then, this bearing installed on the tapered shape
of the roll, and the clearance of the bearing need to be check with a feeler gauge with a specific
range based on the bearing diameter. Hydraulic nut used to compress the tapered shape roller
then fit the bearing in its housing. Last, the lock screw was installed to make sure the bearing
stays in place.
Conclusion: The bearing must be inspected very detail, to avoid any sudden incident or
damage when roller running for the long term in the paper machine. The clearance had to make
sure it in the bearing clearance range prevents the bearing too tight/loose. If too tight the bearing
will become hot when rotating in a long time and lessen the bearing reliability and if too lose
it will slip and the position not aligned.
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Figure 38 Scalling Rust Figure 39 Apply Primer Coat paint

Figure 37 Roller Bearing Inspection
Figure 40 Applying Yellow Paint Figure 41 Install Spherical Roll Figure 42 Check Bearing
Bearing Clearance
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2nd Shutdown
Change Forming Roll
Forming roll is one type of roll that is involved in paper production. The stock continues
along, being pressed between the wires and vacuum supplied to drawn off and remove more
water.
Figure 43 Install New Forming roll process
Problem: The Forming roll has been used almost 6 months and needs to be change caused by
suspected the net layer of the forming roll torn that results in the poor quality paper produced.
First layer of the forming roll had been worn and tear caused it forming and suction process
does not meet the specification.
Solution: By changing the forming roll, it improved the paper quality with no wrinkles. This
was big opportunity for me, had chance involve in changing paper machine roll process.
Conclusion: This task was very heavy and need to be handled carefully by the expertise
because it involved the heavy load. Totally one in-charge and 5 contracts had be assigned to
perform this work. All the pipeline and gauge connections connected properly to make sure it
works smoothly. The bolt had been tightened and the roller had been checked no rub with other
or frame.
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Spray PMT Label of Dryer Cylinder
Figure 44 Labeled Dryer Roll
My second task during the paper mill shutdown was spraying the label for dryer cylinder.
The dryer cylinder is where the paper is fully dried. There was 36 stage of dryer cylinder
involve in the paper drying process.
Method: All the 36 dryers cylinders need to be label, it needs to be inspected by DOST
evaluation. The surface of the dryer cylinder frame was greasy and need to be clean first before
applying paint spay.
Conclusion: This work needs to be done neatly due to evaluation by DOST. Black paint used
as the background colour while white be the labelled dryer number. During the shutdown, the
dryer does not operate, this painting task cannot be performed during on-run, because this dryer
sections are being closed and steam being supply into the space to help remove water process.
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Workshop in Fabrication Team
Figure 4 Machining Area Figure 46 ServicingArea
Figure 47 Fabrication Area Figure 48 Electrical Area
Workshop is a space that establish where manufacturing, handicrafts, making, repair or
service things fully equipped with tools and often machines. All pump, motor, gearbox etc.
bring in here to be serviced. There was four team divide in the workshop based on it task,
machining, service and repair, fabrication and electrical. It worked on specification task or
problem facing on that time. If the pump need to some part to be customize such as create new
key or check the straightness of the shaft, after service has de-assemble the pump it will pass it
to machining team in checking the straightness and create new key to prevent the impeller loose
and collide with the pump casing. Then, if the thing involved with hot work and fabricating,
fabrication team that was fitter and welder will take the task. As a welder and fabrication team,
we do not to involve in servicing job, we more on designing and fabricating task. This task
involves with many hot tool and machine such arc and tig welding machine, auto-cutter
machine, angle-grinder machine, hand and table drill machine and other. In this team, I had
learned many hand-on, practically in handling those machines and the proper way in using it.
This hand-on is more on technical process and skills.
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Fabrication Process
Problem/ Ready to
Design Material Fabrication
Request Used
Fabrication always happen when there are any problems occur that required modification
of things to improve the system and request from the operation in paper mill to easy their task
handling the paper machine flow.
For example, Alkyl Ketene Dimer (AKD) sizing filter, is a chemical that is used in alkaline
or neutral papermaking conditions to provide certain level of hydrophobicity to the paper and
board always reported facing clog. Then, it disturbs the quality pulp produced. The
Maintenance Mechanical Department received the report from Chemical Preparation Team
then assigned the task to Fabrication Team of Workshop.
During designing, the fabrication team need to brain storming in solving the problem, that
prevent the clog from happen. Design created and planned must full fill the requirement and
safe to use also working efficiently. Then, material to be used decide to fabricate the AKD
sizing agent filter.
That how normally, fabrication need or happen during I assigned to this workshop.
Experience was very helpful in this process that help to build confident and produce efficient
product.
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Figure 5 Defoamer Pump Stand Figure 50 AKD Filter Figure 51 Ladder for Fire
Extinguisher
Figure 52 Repair Ladder
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Welding Machine
Welding is a fabrication process whereby two or more parts are fused together by means of
heat, pressure or both forming a join as the parts cool. Welding is usually used on metals and
thermoplastics but can also be used on wood. The completed welded joint may be referred to
as a weldment.
How welding works?
Welding is a high heat process which melts the base material. Typically with the addition
of a filler material. Heat at a high temperature causes a weld pool of molten material which
cools to form the join, which can be stronger than the parent metal. It can also use a shielding
gas to protect the melted and filler metals from becoming contaminated or oxidised.
Figure 53 ARC Welding Process

ARC Weld
This category includes a number of common manual, semi-automatic and automatic
processes. These include metal inert gas (MIG) welding, tungsten inert gas (TIG) welding also
know as gas tungsten arc welding (GTAW). These techniques usually use a filler material and
are primarily used for joining metals including stainless steel, aluminium, nickel and copper
alloys. Arc welding processes are widely used across industries such as oil and gas, power,
aerospace, automotive, and more.
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Safety
1. Wear personal protective equipment, heavy leather gloves and protective long-sleeve
jackets.
2. Wear goggles and welding helmets with dark UV-filtering face plates.
3. Avoid from expose to dangerous gases and particulate matter.
Type of Rod
Choosing/using type of rod is very important based on used purpose, material surface,
metal thickness and gap etc. Commonly used in this workshop was stainless steel (309,316L),
7018 and 6013 to joint mild steel, weld leak pipe and fabricate thing. Wrongly used of rod,
may result to low strength joint and shorten the use of welded objects.
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Grinder
Grinder is one of power tools or machine tools used for grinding, it is a type of machining
using an abrasive wheel as the cutting tool. Each grain of abrasive on the wheel's surface cuts
a small chip from the workpiece via shear deformation.
Used to finish workpieces that must show high surface quality e.g. low surface roughness
and high accuracy of shape and dimension. As the accuracy in dimensions in grinding is of the
order of 0.000025 mm, in most applications it tends to be a finishing operation and removes
comparatively little metal, about 0.25 to 0.50 mm depth. However, there are some roughing
applications in which grinding removes high volumes of metal quite rapidly.
Angle Grinder
Figure 54 Cutting Process
An angle grinder, also known as a side grinder or disc grinder, is a handheld power tool
used for grinding (abrasive cutting) and polishing. Although developed originally as tools for
rigid abrasive discs, the availability of an interchangeable power source has encouraged their
use with a wide variety of cutters and attachments.
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Abrasive Saw
An abrasive saw, also known as a cut-off saw or chop saw, is a circular saw (a kind of
power tool) which is typically used to cut hard materials, such as metals, tile, and concrete. The
cutting action is performed by an abrasive disc, similar to a thin grinding wheel.
Abrasive saws typically use composite friction disk blades to abrasively cut through the
steel. The disks are consumable items as they wear throughout the cut. The abrasive disks for
these saws are typically 14 in (360 mm) in diameter and 7⁄64 in (2.8 mm) thick. Larger saws
use 410 mm (16 in) diameter blades. Disks are available for steel and stainless steel. Abrasive
saws can also use super abrasive (diamond and cubic boron nitride or CBN) blades, which last
longer than conventional abrasive materials and do not generate as hazardous particulate matter
Uses of Grinder and Abrasive Saw: Removing excess material from a piece. There are
many different kinds of discs that are used for various materials and tasks, such as cut-off
discs (diamond blade), abrasive grinding discs, grinding stones, sanding discs, wire brush
wheels and polishing pads
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Safety:
1. Wear safety glasses
2. Double check the discs had been tighten
3. Hold the grinder in correct position
4. Aim the grinder properly
5. Stay focus when operating the grinder
Figure 55 Cutting Disc (Black) & Polish Disc
Type of Disc used are very importance to be determined before operating the grinder. It
should be used just for specific task such as cutting disc, just use to cut plate or metal, cannot
be used to polish if not, the disc may be shattered and caused injuries to user and surrounding
people. The disc also needs to tighten carefully, to avoid it from unrooted from the grinder.
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Oxy-Fuel Cutter
The Portable Oxy Fuel Cutting Machine, HK-12 Beetle is an affordable, portable, oxy-fuel
cutting machine also known as auto cutter. It is known as one of the best portable cutting
machines in the industry. This portable gas cutting machine can be used with one or two oxy-
fuel torches, has a solid aluminium body. The improved transportability and operability will
surely contribute to rationalization and labour savings of cutting operation.
Figure 56 Cutting Chequer Plate Process
Uses: Can perform straight line cutting, circle cutting, and bevel cutting. In our workshop, to
fabricate long piece of plate and fabricate many metal works, the auto cutter used the cut-off
the time produce constant straight line. With straight cutting it results neat fabricate products
and precise dimensions.
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Safety:
1. Remove all combustible materials such as wood, paper near the cutting location.
2. Wear suitable PPE before start light up and cutting process.
3. Careless handling of a lighted blow pipe (torch) resulting burns to users or others (torch)
resulting burns to users or others.
4. Shut off the torches and cylinders when not in use. Don’t leave a lighted torch on
platforms or floors. Then, turn the gas supply off at the cylinder.
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CHAPTER 4
Conclusion
In review of 10 weeks of In-Plant training at Asia Honour Paper has been an excellent
and rewarding experience. I have been able to meet and network with so many people that I
am sure will be able to help me with opportunities in the future. I also learned how to work as
a team and real-world situation of which are not taught in the classroom.
One main thing that I have learned through this internship is time management skills as
well as self-motivation. When I first started I did not think that I was going to be able to
make myself sit in an office for eight hours a day, five days a week. Once I realized what I
had to do I organized my day and work so that I was not overlapping or wasting my hours. I
learned that I needed to be organized and have questions ready for when it was the correct
time to get feedback.
From this internship and time management I had to learn how to motivate myself
through being in the mill for so many hours. I came up with a few proposals and ideas that
the company is still looking into using. I enjoy this line of work, but I am not sure if there is
enough room to grow through this company. This was an excellent experience and I hope that
others intern student got as much out of it as I did.
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Recommendation
Based on the industrial training that has been done, there is some recommendation
need for the final year project work. First of all, it is suggested to implement a real
maintenance industry during laboratory session. On the other hand, students can implement
preventive maintenance working instruction by refer the manual instruction of the equipment.
So those, students can study the consequences of problem machine. Other than that, it can
also implement total productive maintenance around building campus.
References
1. Hills, Richard, "Papermaking in Britain (1488–1988), “A paper machine (or paper-

making machine) is an industrial machine which is used in the pulp and paper
industry to create papers in large quantities at high speed.
https://en.wikipedia.org/wiki/Paper_machine
2. Rupesh Kumar Verma, Manager-HSE at United Breweries Ltd (Jul 23, 2015) “Safety
In Gas Cutting” https://www.slideshare.net/RupeshKumarVerma3/safety-in-gas-
cutting
3. World Economic Forum, (2020-04-20), Royal Golden Eagle (RGE, also known as Raja
Garuda Emas, previously Raja Garuda Mas), http://www.sukantotanoto.net/
sukantotanoto and https://en.wikipedia.org/wiki/Royal.Golden.Eagle
4. Rawool, Vishakha Waman (2011). "Chapter 6: Hearing Protection and Enhancement
Devices". Hearing Conservation: In Occupational, Recreational, Educational, and
Home Settings. Thieme. pp. 136–173, https://en.wikipedia.org/wiki/
Hearing_protection_device
52

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Civil Engineering (infrastructure) (Universiti Teknologi MARA)

StuDocu is not sponsored or endorsed by any college or university

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

INDUSTRIAL TRAINING TECHNICAL REPORT

Name: Syahin bin Shaifuddin

Course: Bachelor of Mechanical Engineering

Training Period: 10 Weeks

Industry Name: Asia Honour Paper Sdn. Bhd.

Downloaded by Carissa May Maloloy-on (carissamaymaloloyon@gmail.com)

INDUSTRIAL TRAINING TECHNICAL REPORT

ASIA NONOUR PAPER SDN. BHD.

Period of Training: 20 July 2020 – 25 September 2020

SYAHIN BIN SHAIFUDDIN

This Technical Report for Industrial Training is submitted to

Faculty of Mechanical Engineering,

Universiti Teknikal Malaysia Melaka

In partial fulfillment for Bachelor of Mechanical Engineering

Faculty of Mechanical Engineering

University Teknikal Malaysia Melaka

Downloaded by Carissa May Maloloy-on (carissamaymaloloyon@gmail.com)

Downloaded by Carissa May Maloloy-on (carissamaymaloloyon@gmail.com)

Downloaded by Carissa May Maloloy-on (carissamaymaloloyon@gmail.com)

This report describes my activities as long as I undergo industrial training at the

entirely from recycled paper.

Teknikal Malaysia Melaka.

Downloaded by Carissa May Maloloy-on (carissamaymaloloyon@gmail.com)

tunggal bersumberkan sepenuhnya daripada kertas yang dikitar semula.

Teknikal Malaysia Melaka.

Mudah-mudahan, maklumat yang dijelaskan dapat memuaskan pembaca sekaligus

berada di persekitaran tempat kerja. Insya Allah.

Downloaded by Carissa May Maloloy-on (carissamaymaloloyon@gmail.com)

PREKASH AMALDASS, Mechanical Manager in Maintenance Mechanical Department for

the completion of this training.

assist in real industry job scope throughout during of this training.

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Welding Machine .......................................................................................................................... 44

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especially in the increasingly sophisticated technology and rapid development, it is necessary

familiar with real work environment.

Industrial training programme is a requirement for students to graduate with Bachelor of

theories that they learned in the university.

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actual industry environment.

• To gain knowledge via working experience thus improving technical knowledge.

• To adapt with working environment and practice working efficiently.

• To work effectively as an individual and team members.

environment, and training activity.

in Asia Honour Paper Sdn Bhd.

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ASIA HONOUR PAPER Mission

To achieve sustainable profitability through innovative, good-quality

Maintenance Department Mission Statement

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Company Core Value

Figure 1 TOPICC Core Values

• We are aligned by our common purpose and work

together as a COMPLEMENTARY TEAM

• We take OWNERSHIP to achieve outstanding results

and seek value all times

• We develop our PEOPLE to grow with us