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TABLE OF CONTENTS
No. Title of section Page
1.0 Table of content 1
2.0 Introduction
Information of company
Description of company
Main activity/ production of the company
Practical training overview
2-4
3.0 Industrial environment 5-6
4.0 Industrial experience
Detail summary of tasks
7-13
14-44
5.0 Industrial project 45-47
7.0 Summary 48
8.0 References 49
9.0 Appendix 50
1
1.0 INTRODUCTION
1.1 History
The establishment of the Office of Facilities Management in UiTM SHAH
ALAM was in 1972 and it is so called Engineer’s Office at that time. After that, in
1982 they changed its name to Development and Maintenance. In 1994, this
Development and Maintenance is well known as the Office of Development and
Maintenance.
The Office of Development and Maintenance was separated under a separate
administrative head on 15th of September 1995. This separation is because the
function of the Office of Development and Maintenance are growing drastically by
the development of building throughout UiTM. Both of these departments are placed
directly under the Office of Chancellery. Institute of Technology MARA, ITM has
been declared as Universiti Teknologi MARA in August 1999 and this causing the
development of the role of the Maintenance Office to be wider for which it is
directly involved on the growth, development, and advancement of the university.
The vision achievement towards becoming an educational institute global public has
been strengthen for Universiti Teknologi MARA and during this period of time,
restructuring and renaming of Maintenance Office was made on 4th of January 2006
and officially changed its name to Office of Facilities Management.
1.2 Structural of Main Activity
I have been attached to one of the department under Office of Facilities
Management for which into Mechanical System Operation Department (BOSIM) for
my industrial practical training that relating to my course which is Mechanical
Engineering. What BOSIM does is they manage to provide services such as
maintenance work in UiTM that involves mechanical field. There is scheduled
maintenance and periodic maintenance.
2
Mechanical System Operations Division (BOSIM)
Air Conditioning
Unit
Lift & Fire Extinguishers
Unit
Project (M&E) Unit
Engineering Complex Zone Unit
Vehicle Workshop
Unit
Water Supply & Sanitary
Unit
These are all the maintenance work field that covered by the BOSIM.
Figure 1.1 Schematic diagram of BOSIM structure
1.3 Objective of Practical Training
There are several objectives of the practical training which are:
1. To expose our self to actual working culture and industrial practice.
2. To allow our self to extend our theoretical knowledge into practice.
3. To motivate our self to practice the right working attitudes and
professionalism to increase our employability potential.
4. To facilitate our self to potential employers.
5. To experience the application and management skills of engineers.
3
1.4 Scope of Training
For the scope of training, I had been given a schedule for the practical training for
the whole period of my attend for this department. Mr. Muhammad Zulhadi Bin
Jaffar has been assigned to be my supervisor that in-charge during my training here.
The practical programme is divided into two, one is The Introduction to the Services
and Maintenance Work and the second one is The Project Assignment of Changing
the Air-Conditioning System for Academic 3 and FSKM. It is all compile for only
twelve weeks.
Task
Week
1 2 3 4 5 6 7 8 91
0
1
1
1
2
Split/ Inverter Air conditioning
Central Air conditioning
Fire Fighting
Lift
TES Air conditioning (S&T)
Water Supply
Sewage Treatment Plant (STP)
Vehicle and Automobile Fleet
Management
Project Assignment
Preparation Reports writing
Figure 1.2 Schedules for the Practical Training
4
2.0 INDUSTRIAL ENVIRONMENT
2.1 Adaptation and Adjustment to the Industry
When I go to do the practical training, I have learned too much experience from
peoples around me. The experience that I get during my practical training is very
difficult to get if I not involved in this practical training.
The very valuable experience that I get during my practical period is learned to
communicate more effectively with the executive level and technician’s level. If we
are in the some organization the most important thing is we must solute to the
executive level. Also we must use the polite word when we talk to them. I also
learned how to communicate effectively with the contractors and third party
inspectors.
Besides that, I also learned about the safety awareness. I can’t take for granted for
this subject. So, from first day I doing my practical training, I had exposed to the
safety requirement that I must be followed. I also attended the ’GreenCard course’ to
give me more input about safety during my practical session. So, the entire safety
requirement I must followed to avoid any accident.
Also, I learned about the responsibility that must be exists in my soul. This is
because, the ethics to become as a professional Engineer, I must be responsible for
the whole thing that I done. So during this my practical training, I had learned this
ethics that mean I must be responsible to the entire task that given to me. I must
complete it until get I achieve the goal.
5
2.2 Practice of Occupational Safety and Health Environment
In Malaysia, the design and manufacture of the Group’s energy systems
strictly complies with various criteria established by the local Department of
Occupational Safety and Health (DOSH) and local regulations such as the Factory
and Machinery Act, 1967 and the Factories and Machinery (Steam Boiler and
Unfired Pressure Vessel) Regulation 1980. The Group’s energy systems further
complies with the ISO 9001 Quality Management Standard as well as international
design, manufacture and assembly codes such as the British Standard and the ASME.
In addition, Lloyds Register, an internationally recognized inspection company
endorsed by the DOSH, inspects each pressure vessel of the system during the
manufacturing, commissioning and installing stages.
So from this attention, I have practiced to wear boots and safety helmet during site
visit. Washing hands is a must after come back from site visit to avoid any
infections.
6
3.0 INDUSTRIAL EXPERIENCE
3.1 Duties and tasks that comply with the training schedule.
This is where all the summary and chronology description of duties and tasks
that had been carried out during the 3 month training.
Week/Date Activity Description
Week 1/
9-13 July 2012
1. Introduction to Facilities Management
- Briefing from Mr Zulhadi, my supervisor for this
training, about the organization of this department.
- Introduction to the staff at the office by meeting them
on my own.
2. Receiving schedule for my training session.
- There is a division of week with the department that I
should explore throughout my practical training.
- With the schedule given, I’ve started my site visit at
Faculty of Electrical Engineering Block 4 and
NanoElectronic Center with Mr Razi, air conditioning
technician. The problems are about the load of the site
increased with the new equipment incoming.
3. Division from supervisor to form two groups of practical
students.
- Supervisors explain about the role as practical
students.
- From the division, I’ve started with the first
department which is Split/Inverter Aircond by getting
explanation from the engineer assistant, Mr Norfandi.
4. Attending course made by Construction Industry
Development Board Malaysia (CIDB)
- This course was lectured by Mr Edham Khalid from
Occupational Safety & Health Centre (OSHC).
- Talking about the awareness of safety during work at
different workplace.
5. Notes about split unit and inverter airconds are given.
7
Week 2/
16-20 July 2012
1. Site visit at the Faculty of Law.
- Services done by STR contractor on indoor ceiling
cassette unit.
- Brief explanation from the technical staff about
inverter VRVII outdoor unit (DAIKIN) including the
advantages and also the services and maintenance
progress.
- Schematic diagram of an inverter system, simple air-
conditioning cycle and the error code for the VRV are
given by the technical staff.
2. Site visit at the Faculty of Hotel.
- Master check was done after the complaint made by
the lecturers and students.
- They using the manifold gauge to determine the high
and low pressure of the pipe.
- Standard for high pressure reading is 250 psi and for
the low pressure reading is 70-60 psi.
- Refrigerant used for that system are R-22.
3. Site visit at the Faculty of Mass media & Communication.
- There is a problem of aircond not functioning. After
troubleshoot, we found out that power supply not
reached the PC Board. This is caused by the fuse
burned.
4. I’ve been thought by Mr Norfandi about the theory of
water-cooled chillers system.
- Further explanation on determining suitable air-
conditioning system for a certain room.
- 4 step of them that must follow:
Calculate the area of the room and multiply
with factor U.
Divide with 10000 to get horsepower.
Refer to catalogue to choose the aircond.
Evaluate easiness of maintenance.
8
5. Method of servicing and maintaining.
- Cleaning the filter once every two month using water
spray or further cleaning using chemical.
- If the dust amounts are too critical, we need to
overhaul by open it one-by-one.
- Flushing the drain pipe using vacuum or injecting
water.
6. Mr Deli gives introduction to Fire fighting and Lift.
- Class were held at the BOSIM workshop.
- Three composition that must be together to form fire:
Heat
Oxygen
Burning material
- Medium to fight fire such as hose reel, water sprinkler,
wet riser, dry riser and etc.
- In the pump house, there are standby pump, duty
pump, test pipe, meter switch and etc.
- Counterweight was used to reduce the electric
consumption of the elevator.
- Worm gears were used for the elevator system to avoid
slips.
7. Site visit at the Science and Technology building.
- There is a motor house at the attic of every block for
the elevator.
- Governor is part of the elevator. Function as to stop
the elevator when it moves at massive speed.
- Every block of elevator there is one BOMBA lift car
allocated. During fire alarm, only this lift car can be
used and the switch for this lift car is at ground floor
beside the lift car entrance door. The usage is limited
to BOMBA person only.
- The guide rail is to maintain the position of the lift car
when it moves.
- There is a key to open the lift car door manually for
9
the purpose of service and maintenance and also for
rescuing people.
- Mr Afzal brought us to the fire fighting section within
the same building.
- He showed the location of the wet and dry riser, the
piping, and also the location they placed the hose reel.
- The main pump house located at the Faculty of
Chemical Engineering.
- Jockey used when 5% drop in pressure.
- Duty pump switched on when pressure drop another
25%.
Week 3/
23-27 July 2012
1. Getting to know the history of UiTM Shah Alam.
2. Site visit at the Science & Technology building for
Thermal Energy Storage (TES).
- Mr Shukor explains the surface of TES air-
conditioning system at S&T.
- Go to the cooling tower location whereby 8 tank of
cooling tower are placed. This tower is to take out heat
from the condenser from chiller plant.
- Go to the underground Ice Cell located at the parking
lot of Chemical Engineering Faculty. There is where
45 units of Ice Cell are placed.
- They use fluid mixture of glycol and water as the
working fluid to transfer heat to the Ice Cell during
office hour.
- Go to the chiller plant. There is four chiller and they
run alternately.
- Go to the control room where we can see the system
movement and we can control any movement from
there.
3. Mr Azman gives the lecture about Water Supply in UiTM
10
Shah Alam.
- There 3 water supply system that UiTM Shah Alam
use:
Section 2, Shah Alam
Pusat Islam, UiTM
Kolej Mawar, UiTM
- Handout and map about water supply been given.
- Go to the site at Section 2 and Pusat Islam to see the
pump house and the suction tank.
- Go to the biggest reservoir in UiTM which can store
water up to 2MG. climb the reservoir and get in to see
the area inside.
4. Sewage Treatment Plant (STP) site visit.
- We were brought to Kolej Mawar sewage treatment
plant which was a Malaysian design.
- Cover for S&T building, Kolej Mawar, Kolej Melati
and Dataran Cendikia.
- Beside this treatment plant is another treatment plant
which was a British design and it cover for Kolej
Teratai and Kolej Anggerik.
- Another treatment plant was located at Gate 4 UiTM.
This is all-British design and cover for ROTU building
and Kolej Perindu.
- Just beside the plant is a high-clean treatment plant
and it covering for DATC building only.
- The last location of the treatment plant is at the main
entrance of UiTM and it is a Malaysian design and it
covers all the Zone 1 section.
Week 4/ 1. Introduction to Vehicle Unit.
11
30 July-
3 August 2012
- Mr Ihsan as the engineer gave the lecture about the
vehicle unit in detail.
- Explaining the movement of a car from inner part of
the engine to the last outer mechanism.
- Introducing staff members.
- Mr Rafine explains about Fleet Management System
in detail.
- Go to the workshop to see engine parts for car from
the top and also from the bottom of the car.
- They show the differentiation of diesel engine and
petrol engine and also a V6 engine and a normal piston
engine.
2. Go to the workshop
- Determine tyre specification from the tyre itself.
- Changing the car tyre by practicing the correct
procedure.
- Site visit at the bus depot near Gate 2 UiTM.
- Identify how the bus engine works.
- Visiting the generator-set trailer that can generate
power supply for one housing state.
3. Handouts of the detail engine part are given.
4. Meeting with supervisor, Mr Zulhadi and discuss about
the assignment that he going to give.
5. Taking notes from Mr Aizudin for Thermal Energy
Storage (TES).
6. Go to the Bukit Raja area workshop that have contract
with UiTM.
- Balancing and tyre alignment were done.
Week 5/
7-10 August
2012
1. Go to the EON Service Centre at Glenmarie.
- Contractors are used as the worker.
- They showed us the correct procedure on balancing
and aligning the tyre.
- They divide different part of car to different
12
contractor.
2. Receiving Plan for Academic 3 and FSKM building.
3. Doing research on both Academic 3 and FSKM building
in all scope that involves for the assignment.
Week 6 –
Week 11/
13 August –
21 September
2012
1. Site visit at BadanBas SDN. BHD located at Kajang,
Selangor.
- I’ve been showed the process of making the bus body
from the given bus chassis from other manufacturer.
2. Started the project assignment after the task being given
from the supervisor.
- Done the analysis about the cooling load, the capacity
of current aircond, the costing of the current and new
aircond and etc.
- On the way of choosing the suitable air-conditioning
system.
- Listing the task to complete the project.
- Dividing the task equally to the group member for a
better accomplishment of the project.
- Do some finding about the building itself by doing site
visit.
- Collecting data from technicians.
- Receiving catalogue from the contractors.
- Make an interview with the project engineer, Mr
Fizan.
- Making the draft of the project for the supervisor to
check from time to time.
- Discussing with the supervisor about the calculation
involves.
- Discuss within team member on how the progression
goes.
- Editing the report of the project.
- Choosing the suitable air-conditioning system.
13
Based from the table shown, those are the activities, duties and tasks as a practical
trainee does at Bahagian Operasi Sistem Mekanikal (BOSIM). Most of the site visits
are done in UiTM Shah Alam. Those are the needs and requirement for us to explore
the engineer work at BOSIM. From what I can see, BOSIM totally does the service
and maintenance for the whole UiTM Shah Alam for the mechanical system exists.
All the servicing work are done when there are problems and complaint from the end
user and if not, they’re just doing the maintenance as schedule. I also had a project
assignment to be completed. We as a team had to do some research and finding on
the problem given which was a maintenance problem that they had involving two
building. Our task is to choose the suitable and the most convenience air-
conditioning system to solve the problem.
(Additional information such as project report can be refer to appendix)
14
3.2 Detail summary of tasks.
All the duties and tasks that have been carried out are for service and
maintenance work in UiTM Shah Alam. There are all seven systems that this
BOSIM department cover for UiTM. Each system needs to be learned in terms of
basic knowledge in order to understand properly. All the duties and task are as the
follows:
3.2.1 Air conditioning system
Air conditioning system is a must have facility for a closed building where there
are a load in it such as human being and equipment for example. This is to create a
comfort zone for the end users. There are many types of air conditioning system that
has been designed nowadays. During my practical, I have learned the types of air
conditioning system that UiTM Shah Alam used. There are:
- Split unit
- Centralised
- Inverter
All the types of air conditioner are using the same refrigeration cycle process such as
compression, condensation, expansion and evaporation. The cycle begins when a
low-pressure of refrigerant gas has been compressed by compressor and become as a
high-pressure gas. Then, it flows to condenser unit and condensed until liquids state
are formed. The third process is the high-pressure liquids of refrigerant are converted
to low-pressure liquids. For the last process, the evaporator is used to absorb heat
from the inside and removed it by using refrigerant. In this process, the liquid state is
converted into low-pressure gas. The same refrigerant is used during this cycle.
Figure The basic cycle for air-conditioning.
15
I used to follow the contractor and technicians doing their jobs. This is to completing
my task in identifying the type of servicing and maintaining procedure that has to be
done. With my bare eyes, I can see all the parts that has been explain in classes
before for real.
a) Split air conditioning unit
A split air conditioning unit has two types of system which are single split unit
and multi-link split units. This type of air conditioning unit has a separate part of
indoor and outdoor unit unlike window unit, which they come in packages where the
indoor and outdoor are fixed together. Split unit are installed either in the form of
back to back or not, depends on the location. Single split unit has only one indoor
and one outdoor but for multi-link split units, it has two or more indoor unit and only
uses one outdoor unit. I divided into two units, indoor and outdoor unit. Each unit
has their own procedure for servicing.
i) Indoor unit
The inspections and services for indoor unit are done for every two month. The
services are as follows:
- To clean filter
- To clean blower fan
- To clean body
- To check electrical control
- To check and release starter or transformer
The filter for wall mounted can be cleaned by using pressurised air blower. It is not
encourage using pressurised water to avoid some complication on the component
inside the indoor unit. But if the filter is so critical and water cleaning is needed, we
can just take out the filter and wash with water and let it dry first before install it. For
blower fan, they used to clean the blower fan by wiping the surface of blower to
ensure refrigerant cycle is smoothly. This is all done to ensure the fouling factors are
avoided or reduced.
16
Here are examples of servicing work done for wall mounted and ceiling cassette air-
conditioner.
ii) Outdoor unit
The inspections and services for outdoor unit are done for every two month. The
services are as follows:
To clean condenser with water
To clean body
To check electrical wiring
To check gas
To check and release screw to mounting
To check and release cooper pipe
Below are the procedures of servicing work for outdoor unit of split sir conditioning.
Condensers are the part which will be quickly got dirty due to dust that clogged at
the fin. So it is necessary to clean the condenser coil and remove the clogged dirt
with water and if it is too critical, we have to use the chemical detergent to get rid of
them.
17
Figure The blower fan for ceiling mounted air conditioner
Figure The filter for wall mounted air conditioner
Here are the procedures on cleaning and servicing the outdoor unit. Here they use
chemical because of the outdoor unit fin is so critical with the dust loads.
18
Figure The process of cleaning the condenser
Step 1: Flushing water to remove dirt.
Step 3: Allow chemical for a while to deteriorate the dirt and
dissolve any organic matter
Step 4: Wash the condenser coil thoroughly using water until the entire chemical is completely removed
Step 2: Spraying chemical detergent onto condenser coil
b) Inverter air conditioning unit
Inverter in an air conditioner used to control the speed of the compressor motor
to allow continuously regulated temperature. Therefore, it can save up to half of the
electrical power usage. There are three type of air conditioning that uses inverter that
exists in UiTM which is VRV Daikin, VRF Mitsubishi and VRF Toshiba.
The three figures above shows the type of air conditioning systems that are
using inverter. They can be classified as centralized unit of air conditioning because
the outdoor unit is located together at one location. VRV is stands for Variable
Refrigerant Volume and VRF is Variable Refrigerant flow. The reason why only
DAIKIN using VRV is that they have trademarked the name for their own brand to
make it differ from others. Three of them have their own advantages and
19
Figure VRV Daikin
Figure: VRF Toshiba
Figure: VRF Mitsubishi
disadvantages. Their maintenance and servicing are different due to the design.
Following the contractor gave me the opportunity to know the detail on how they
done the maintenance and also the service. There are several site visits that I’ve done
for the inverter air conditioning unit.
- VRV DAIKIN
Centralized unit VRV II DAIKIN Inverter is used at the Faculty of Law. They have
done servicing for the inverter. There are two types of servicing which are servicing
for outdoor unit and indoor unit. The normal service for indoor unit is twice a year
by doing the servicing on the filter and motor blower. For outdoor unit, the normal
service is also twice a year. It is necessary to ensure the fin coil is always clean from
dirt and we can clean it using chemical or pressurised water to wash out any dirt. For
detection any leakage in pipe, they will put an amount of nitrogen gas and stay for 24
hours. Then they will test the pressure reading and if any drop of reading, leakage
occurs. When there is a problem, there is an error code given for the specific part that
having the failure including the outdoor and indoor unit. It is a board that displaying
the code called PC Board.
- VRF TOSHIBA
VRF TOSHIBA is used to cover for air conditioning unit at UiTM Hotel. The
maintenance was done there. The contractor is responsible to inspect the error
occurred that cause the supply air doesn’t make the room at the desired temperature.
They’ve done Master check for the VRF which is the main of all of the VRF. The
procedures involved during the inspection are as follows:
- Check the high and low pressure whether it is enough or not by using
manifold gauge. Blue colour hose determine low pressure and it has to be 60
to 70 psi while the red colour hose to determine the high pressure and the
reading must be around 250 psi. If the pressure is less than the range, it
means that the pressure is not enough to supply the refrigerant. However, if
the pressure is higher than the range, it is necessary to remove the gas. It is
important to ensure gas is enough to make the system well function.
20
- Then, check the current flow by using clamp meter. This is to ensure the
current is less or equal the specification of the outdoor unit required. In this
case, the current required is 18 amps. If the value is higher than 18 amps, it
means that the loads are high and some cleaning at the fin is needed or maybe
there is excessive of gas in the pipe.
21
Figure Manifold gauge
Figure Clamp meter
- VRF MITSUBISHI
The air conditioning unit that cover for Academic 3 is VRF MITSUBISHI. The
maintenance was done there and the faculty involve is Faculty of Mass
Communication. It has been 8 years the air conditioner had been installed and the
issue is the air conditioner is not working. Then after troubleshooting the problem,
the contractor found out that there is no power supply reaches the PC Board. It is
caused by the fuse at the PC Board burn due to current overload. The solution is
changing the fuse to a new one. The price for changing the compressor is RM16, 000
and it is much higher than split unit which is only RM600.
22
Figure The PC board for VRF Mitsubishi
3.2.2 Lift/Elevator system
People used to say it as lift but they can’t find one on the internet. The
correct word that is technically used is elevator. In UiTM there are two types of lift
system used. Hydraulic lift and electric lift. There are categories of lifts at UiTM:
i. Passenger lifts
- Capacity up to 20 people
- Speed range 1-3 m/s
ii. BOMBA lifts
- Capacity 6 to 20 people
- Can only be operated during fire operation.
There are major lifts components that must have for all the lifts system. There
are:
Components/ Function Figure
i. Lift motor
- 2 direction motor to drive the
lift car upwards and
downwards.
23
ii. Selector
- Records position of lift car and
transmits messages to
controller.
iii. Controller
- Controls overall operation of
the lift.
iv. Governor
- Triggering the safety gears to
stop the lift from the over
speeds on it’s downwards
travel.
Major lift components at lift shaft.
Components/ Function Figure
i. Lift car and door
- To contain people and goods
24
ii. Counterweight
- To balance the load of the car to
ease work of motor.
iii. Hoisting rope
- To hoist the car and
counterweight up and down the
shaft via the motor.
iv. Buffer
- To stop descending lift or
counterweight from over travel
by absorbing kinetic energy.
v. Guide rails
- To guide the travel of the car
and counterweight.
Safety features of a lift.
- Speed governor - Overload Non-Start
25
- Buffer - Door interlock
- Safety gear - Door safety shoe
- Brake - Weight closer
- Worm gear
- Thermic devices
- Electrical fuses
- Ropes
Figure The detail parts of the elevator/lifts.
26
There are special elevators in UiTM and it only have at S&T building. They
use the latest technology brought from Schindler. This technology using the system
of controlling the elevator usage according to human traffics. For example there are
4 elevators in each block and each elevator can contain 10 peoples. When there are
15 peoples are coming to the lifts lobby and wanted to go up the building. 3 people
are punching level 5 and 5 people were going to level 10 and another 7 people will
be going to level 7. So the system will instruct the controller to manage the people
equally with their requirement. After the users select their level, the system try to
giving the users instructions to which elevator should they go. For example the
solution was like they send the 3 people who are going to level 5 and 7 people who
are going to level 7 to elevator A. It seems like the quota have reached. So the
system will instruct another 5 people to go to elevator B for level 10 destination. The
system is some sorts like controlling the human traffic at the lobby of elevator.
3.2.3 Fire fighting
There a lots of ways to fight fire. To fight them, we have to know what causes
them to exist. There are three compositions that cause fire. Without one of them, fire
wouldn’t start at all. The three compositions are heat, oxygen and burning material.
The fire fighter or our self especially can settle down the fire burning by determining
the causes. There are types of fire extinguisher build depends on what type of fire do
they have to fight. Some are fire from solids, oil, gases and etc.
There are types of fire fighting system:
i. Small portable fire extinguisher
Figure Range of fire extinguisher.
27
The blue colour tank contains of dry powder, red colour tank contains of water,
cream colour tank contains of foam and the last one is the black colour tank contains
of carbon dioxide, CO2. The maintenance for the extinguishers tanks is done twice a
year and it is recommended from the BOMBA department. This is because they are
the one who will check it from time to time.
Figure The fire triangle.
Below shows the table for the types of fire extinguisher and the types of fire they
distinguish.
Type of fire extinguisher Type of fire
Water Solids
FoamSolids, flammable liquids, cooking oil or
fats
Dry powderSolids, flammable liquids and gasses,
electrical equipments
Carbon DioxideFlammable liquids, cooking oil or fats,
electrical equipments
ii. Fire alarm system
They have designed fire detection and alarm system to give warning of the
outbreak of fire and to allow appropriate fire fighting action to be taken to control
the situation. There are types of fire alarm system:
28
Table The uses of fire extinguisher
Figure The floor plan alarm system.
Figure The alarm system equipment.
The alarm system is detected by using manual break glass by a personal or by
using the detector whether it is smoke or heat detector as shown in figure ... From the
detector, they send to control panel board to trigger the bell at the affected location
or nearest with the location. For S&T building, they are using the iSCADA system
for which the detector will send to the in-charge person about the situation occur to
their phone through SMS. The iSCADA send the detail information in the fastest
time to prepare for any emergency occurrence.
The maintenance for the fire alarm system, the BOSIM does for every 6
month by testing all the alarm system. Services are done when there are problems
occur such as the alarm trigger automatically causes from the short circuit.
iii. Fire fighting system
Fire fighting system is designed to prevent loss of life, destruction of
property and environment when open fire happened. It also helps to avoid the fire
from getting to the unaffected area. Most of the fire fighting systems uses water as
the medium to stop the fire. But some fire fighting system use gases. This is because
they don’t want to destroy the equipment in the locations covered. For example the
server room, computer lab and the electrical equipment storage. But once they have
used the gas extinguisher, they have to change all the piping and gas tank with a new
one. The maintenance is done for every 6 month.
29
There are types of fire fighting system available at UiTM. Those are wet
riser, dry riser, water sprinkler, gas distributor and hose reel. For wet riser, they
supply water to the water sprinkler and those hose reel that are located in a certain
place in the building by using the water storage available in that building. For dry
riser, there are inlets for the BOMBA to fix in their hose to supply water to certain
water sprinkler system or fire hydrant. Maintenance for those systems are done twice
a year and they do regular check for any kind of dripping occurs.
3.2.4 Thermal Energy Storage (TES)
Thermal energy storage (TES) is a new technology to supply an air conditioning
system to an enclosed building. This technology application can cut the cost of the
power consumption based on the tariff from Tenaga Nasional. This is because the
tariff is low for the non-office hour usage. So this thermal energy storage (TES) only
consumpt most of the electricity at night which starts at 10.00 p.m. to 6.00 a.m. Then
from 8.00 a.m. to 5.00 p.m where the tariff of electricity became normal, they only
need simple machines to run the system and not much of electrical usage at that time.
This thermal energy storage (TES) acts as a battery that can charge and discharged
cooling capacity. It comprises a number of technologies that store energy in a
thermal or ice big compartment for later use. Engineering complex at UiTM Shah
Alam chose TES to provide the air conditioning for the building. There are two
operations involved in TES which is charging process and discharging process.
30
Figure Examples of fire fighting system
Charging process is done at night time between 10.00 p.m to 6.00 a.m and while
discharging process is done at day time which used to cool all the room. Discharging
process is done between 6.00 a.m to 9.45 p.m. The system only rest for 15 minutes
every day.
Mr Shukor, the engineer who are responsible for this whole system
progression. His engineer assistant is Mr Aizudin and the technician is Mr Nasir.
They work as a team in conducting any maintaining or servicing. TES works when
the Ice Cell tank is filled with water submerged a polyethylene tube heat exchanger.
A glycol solution (-3.3°C) flowing inside the tubes causes the surrounding water in
the Ice Cell to freeze. The mixture was 10-15% of glycol in water. The chilled glycol
solution is typically provided by a chiller having 24 tons (84 kW) cooling capacity.
When fully frozen, the Ice Cell stores 240 ton-hour (844 kWh) cooling capacity. It
31
Figure The schematic diagram for Thermal Energy Storage (TES)
requires 10 hours operation of a 24 ton chiller to fully freeze the water in the Ice
Cell. To serve, the ice melted at a rate dictated by load. The glycol solution flows
from the ice cell to the load device. From here we know that the glycol mixtures are
used to freeze the water in Ice Cell during night time and manage to become a
medium to transfer heat to the Ice Cell during operation time of the air conditioning
system. Glycols are mixed with water because they wanted to decrease the freezing
point of water. So that they can cut cost on choosing the fluid medium to transfer
heat by using only the water based fluid.
i. Major component system in TES:
ii. Function of major component
32
Figure Heat exchanger Figure Chiller plant
Figure Ice cellFigure Cooling tower
- Heat exchanger is used to absorb heat and transfer cold air to
building through Air Handling Unit (AHU) and Fan Coil Unit (FCU).
- Chiller plant is acts as the central unit that use automated chiller
control and monitoring system. 2 units of chiller are used for
charging mode and 2 units of chiller are used for discharging mode.
Each chiller consist 900 RT. The chiller used alternately.
- Ice-Cell is used to store cooling capacity. There are 45 Ice Cell tanks.
The Ice Cell stores 844 kWh cooling capacity.
- Cooling tower is used to remove heat from the water supply that
came from condenser. The type of cooling tower used is force draft.
The location of each component is still within UiTM areas. For cooling
tower, there are two stations, one at tower 1 and the other one is at tower 2 of
S&T. For the chiller plant, it is at underground level behind the Faculty of
Electrical Engineering. For the heat exchanger, it is just besides the chiller
plant. The last component location is the underneath the parking lots at the
Faculty of Chemical Engineering.
Figure Entrance for the Ice Cell storage
BOSIM have to always maintain this facility to keep it working all the time.
So they have another office only for S&T building involve the Thermal Energy
Storage (TES) unit. They are doing maintenance for all of the components twice a
year and do the service when needed.
33
3.2.5 Water supply
Water supply is an essential facility that must have in a community. For
example in UiTM Shah Alam. They have 3 pump house located in this university.
This all pump house is to manage the water intake for the community usage. Water
supply from SYABAS, then go to the suction tank. At suction tank, they kept the
water that being given from SYABAS and all the meter for water bill had been
installed there. After the suction tank, they have pump house to pump all the water in
the suction tank to the reservoir. They are series of them and the quantity depends on
the reservoir that needs to be filled. From reservoir they start to distribute water to
the building tank at the roof top mostly.
34SYABA
S
SUCTION TANK
RESERVOIR
PUMP
HOUSE
Figure The water supply system.
- Pump House
It is build to protect the equipment that completing the pumping process
including the pump, valve, control panel, and etc. This one is made for the easiness
of maintenance. It should be enough space for ventilation and lighting must
available for any emergency cases. It should be double door.
Figure Pump
- Reservoir
To keep the water for future use. The storage is for 1 day supply (for the
system in buildings). It must accommodate the precipitation such as frequently clean
and do the maintenance as schedule. Buffer also has to be done for supplement
problem.
35
Figure Reservoir
Detail about the 3 water supply system in UiTM Shah Alam.
i. Pump house 1 at Section 2
Control panel that they use is Ebara Hydro Booster Pump. The pump and
motor used are 4 nos 90 kW 120 hp Ebara Pump Horizontal Multi Stage
Split Casing (Variable Speed). The capacity that they can cover is 800
igpm each. The suction tank installed can store water up to 500,000
gallon. The reservoir for this one system is 2,000,000 gallon.
Figure The 1st system of water supply
ii. Pump house 2 at Pusat Islam
36
RESERVOIR
2 MG
Pump RoomAll UiTM Shah Alam
Control panel that they use is Ebara Hydro Booster Pump. The pump and
motor performances are 2 nos 30 kW 40 hp Ebara Pump Single Stage In
Line Pump (Variable Speed). The capacity that they can cover is 300
igpm each. The suction tank installed can store water up to 100,000
gallon. The reservoir for this one system is 350,000 gallon.
Figure The 2nd water supply system
iii. Pump house 3 at Kolej Mawar
This pump house is a little bit special than the others because it has two
control panels. First control panel that they use is Hydrologic Booster
Pump. The pump and motor performances are 5 nos 5.5 kW 7.5 hp
Hydrologic Pump Vertical Multi Stage In Line Pump (Variable Speed).
The capacity that they can cover is 30 m3 / hour each @ 52 m. The
second control panel is KSB MOVIC HROM HYDRO BOOSTER. The
pump and motor performances are 5 nos 11 kW 15 hp KSB Pump
Vertical Multi Stage In Line Pump (Variable Speed). The capacity that
they can cover is 30 m3 / hour each @ 87 m. The suction tank installed
and the reservoir can store water up to 800,000 gallon.
Figure the 3rd water supply system
37
RESERVOIR
0.35 MG
Pump Room
Pusat Islam, Menara SAAS, Kolej Perindu, Kolej Cempaka Kenanga, Fakulti Seni Lukis dan Seni Reka, Fakulti Sains Gunaan.
RESERVOIR
0.8 MG
Pump Room
Kolej Melati, Kolej Mawar, Kolej Teratai, Dataran Cendikia, Kolej Delima.
The maintenance for the entire pump house are twice a year. But for
servicing depends on the problem faced. Right now UiTM are doing new
pipeline and also in the process of changing the old pipe with the new
one.
3.2.6 Sewage Treatment Plant (STP)
Sewage Treatment Plant is a facility designed to receive the waste from
domestic, commercial and industrial sources. It is important for removing
contaminant form wastewater and household sewage, both runoff (effluents) and
domestic. It includes physical, chemical and biological processes to remove physical,
chemical and biological contaminants. The purpose of STP is to produce an
environmentally-safe fluid waste stream (or treated effluent) and solid waste (or
treated sludge) suitable for disposal or reuse (usually as farm fertiliser).
i. Type of STP
- Imhoff tank
A tank that comprises two chambers positioned one above the other. In the upper
compartment sedimentation occurs with solids passing through an opening into the
lower chamber.
- Package sewage treatment plant
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Package plants require little design work and can be installed quickly although they
require the same operational and maintenance care as conventional treatment plant.
- Oxidation pond
The popular sewage treatment method for small communities because the
construction and operating cost is low.
- Communal septic tank
This tank is usually comprises two chamber and do not fully treat sewage. It requires
regular desludging.
In UiTM Shah Alam, they use package sewage treatment plant. They have two types
of STP design which is design from Malaysia and British. The maintenance and
operation of STP is managed by Water Supply and Sanitary Unit. The purpose of
maintenance and operation is to highlight maintenance problems by monitoring plant
performance, diagnosing causes and providing effective solution.
39
Figure Sewage Treatment Plant for design from Malaysia
Pre-treatment
Secondary treatment
Tertiary treatment
Primary treatment
ii. The process of STP
The process of STP is classified into four stages. The diagram below shows the
process overview for STP.
Pre-treatment – The process that removes the materials from the raw waste water
before they damage or clog the pumps and skimmers of primary treatment clarifier
such trash, tree, limbs, leave and others.
40
Figure The process overview for STP
Figure Sewage Treatment Plant for design from British
Sump tank
Screening
Grit chamber
Aeration
Primary treatment – The process that removes the settled and floating materials. The
remaining liquid may be discharged or subjected to secondary treatment.
Secondary treatment – In this process, the treatment is used to remove dissolved and
suspended biological matter.
Tertiary treatment – This process is needed to allow rejection into a fragile eco-
system. The water produced from STP is discharged into a stream, river, bay, lagoon
or wetland.
iii. The process flow of STP by doing site visit.
There are some places that I went in order to know the real process flow of STP. Mr.
Azman who is assistant engineer from Water Supply and Sanitary Unit showed me
the process flow of STP. All STP in UiTM Shah Alam have the same process flow
because they use package type of STP. Even though the type of STP is same, the
design is different. From the observation, I conclude that STP that designed by
Malaysia is quite complicated than STP that designed by British.
41
Driver sends vehicle to the
workshop
Foreman inspects the vehicles then
approved by technician
Vehicle sent to panel workshop
Driver picks up the vehicle
Maintenance works done and the
vehicle is sent back to workshop
(UiTM)
Driver logs in the system and file a
complaint
3.2.7 Vehicle and Automobile Fleet Management
i. Fleet Management System (FMS)
FMS is a system that record and store all of the client’s complaint. It helps
tracking all of the maintenance works done on each vehicle. The diagram below
shows the process flow of FMS.
42
Figure The process flow of Sewage Treatment Plant (STP)
ii. Vehicle unit
Vehicle unit consists of two departments which are:
- Managing on route, transport and driver schedule
- Maintenance
Mechanical System Operations Division (BOSIM) is responsible for maintenance
service. There have two type of vehicle:
- Less than 3 ton with 200 units of vehicle.
The examples of vehicle are car, van, SUV, MPV and truck
- More than 3 ton with 60 units of vehicle
The examples of vehicle are bus, lorry and tariler
iii. Maintenance
Types of maintenance:
- Preventive maintenance – The activity that used to prevent failure
- Corrective maintenance – The activity that used to correct the failure
- Statuary maintenance – The works that involved registration, inspection
according to regulation by competent agency.
The servicing for vehicle:
- Less than 3 ton
The servicing is for every 5000 km or 3 months whichever occur first
- More than 3 ton
43
Figure The process flow of Fleet Management System (FMS)
The servicing is for every 5000 km or 2 months whichever occur first
The servicing is similar for both types of vehicle. There are 15 main items that need
to be inspected as follows:
iv. Workshop practice
The practice that involved during workshop is changing a flat tire. Tire is a part
of vehicle that important for movement mechanism. As an owner of vehicle, we need
to know the skill on how to changing a flat tire. Tire need to be changed once it
achieve more than 3 years from the year of manufactures.
We also have been to BadanBas SDN BHD company to see the how bus getting
ready from the manufacturer. It is located at Kajang. The first process after taking
the bus chassis is framing. After framing, they will do panelling. After that they will
take the bus into a big room and done the spraying procedure to paint the bus body.
44
- Brake system
- Oil level
- Gear oil
- Coolant
- Battery water lever
- Dry air filter
- Belting
- Power steering fluid
- Lighting system
- Tire pressure
- Air conditioning
system
- Balancing and
alignment
- Rear axle
- Tuning engine
Then finally they do the trimming process for the finishing.
Mr Ihsan showing the framing process Panelling
Trimming Painting
4.0 INDUSTRIAL PROJECT
During the practical training, I had given a project assignment of changing the air
conditioner system for Academic 3 and lecturer’s building of Faculty of Science
Computer and Mathematics (FSKM). The project is done in groups of six practical
students. The objectives of the project assignment are:
- To decide the suitable new air-conditioning system in order to increase the
‘return of investment’ (ROI) of the existing air-conditioning system.
45
- To save the energy consumption and cost used by the existing air-
conditioning system.
- To improve the existing air-conditioning system for ease of maintenance in
terms of spare parts and access for maintenance works
- To identify the position of each indoor and outdoor units for the new air-
conditioning system.
- To identify the scope of works involved in the installation work for the new
air-conditioning system.
There are several methodologies that we use in order to complete the project. Firstly,
we need to identify the required building for changing the air conditioner by asking
the plan drawing from Project Division. Then, the plan can be used to identify the
number of room required for changing air conditioner unit. Besides that, for
additional input, we need to gather some information such as:
- The history of the building
- The inventory list for existing air conditioner
- The total of air conditioner unit for each building
- The type and condition of required room
- The size for each room
- The cost of maintenance for one year including repair and service work
- The type of air conditioner that need to be installed
There are several calculations involved in this project. The calculation on
determining the cooling load, power consumption and return of investment (ROI) is
used to make a comparison on which type of air conditioning that must be used.
Some equation and formula in calculation are used as the follows:
i. The cooling load
The total cooling load required for the required building is important in order to
choose the type of air conditioner unit on the catalog. Different size of room has
46
different cooling. Therefore, the area of room is defined from the plan drawing.
(Refer on appendix)
Cooling load=Area× factor u
ii. Power consumption
Power consumption can be determined by using the parameter obtained from the
chosen air conditioner unit. The required parameters are the current (Amps) and
voltage (V).There are several considerations need to included in calculation such as
number of day used in a month, working hours, total of month in a year and price
rate of power.
Electricity cost (RM )=Power (kW )×operating hours×day×month× price per kWh
iii. The Return of Investment (ROI)
ROI is used to make a comparison between the existing system and the new
system that need to be installed. We have two options on choosing the type of air
conditioning for both “Academic 3” and “Faculty of Science, Computer and
Mathematics (FSKM)”. For Academic 3, we need to determine ROI for new
installation for window unit and Variable Refrigerant Volume (VRV) inverter unit.
For lecturer’s building at FSKM, we use to determine ROI for split unit and Variable
Refrigerant Volume (VRV) inverter unit.
47
ROI= Estimated investment for new installation costOperation cost
3.3 Relation between the tasks to the Mechanical Engineering course
The project assignment is related to the mechanical engineering course on the
determining the suitable air conditioning system. Air conditioning is one of syllabus
included in Mechanical Engineering course. Besides that, preparing a report is also
related to Mechanical Engineering course. As a student, we have been trained to
write a report for each experiment or work.
5.0 SUMMARY
After I completed this practical training requirement at Mechanical System
Operation Department (BOSIM), under Office of Facilities Management, UiTM
SHAH ALAM, I like to make several suggestions or recommendation that I see it
can be improved the faculty requirement to make sure the other students that will go
to the practical training after this will get more benefits.
1. The faculty management especially Practical Training Committee must
extended the practical training duration to the maximum period, 6 month to
make sure the student able to learn more about the equipment or anything
48
that related to the subject that they learn at UiTM then applying the
theoretical into the task that assigned to them. Besides that, for a long
duration for the practical training student can be assigned to many
department so that they will gain more knowledge during the practical
training.
2. Besides that, the faculty management should be having a good
communication with the industrial management. From that, they will
cooperate to arrange the guideline like a syllabus about what that student
must learn during the practical duration and to make sure that every task that
assigned to the student are related with the subject that their learn in
engineering field.
3. Furthermore the degree student must be exposed balanced to the hands on
and theoretical. That is very important because if student are focus more on
theoretical when they entered to industrial training they don’t know to use
tool for hands on job.
For the conclusion, I was very excited to done the industrial training at this
company because a gain too many experience and valuable knowledge that can I
applied after this especially when I was graduate and face the work challenging that
need me to apply that all knowledge and ethics to make sure I can be one of the
Professional Engineer, With The Bless Of ALLAH S.W.T
6.0 REFERENCES
Manual Pengurusan Kenderaan Universiti Teknologi MARA.
Panduan Penyelenggaraan Kenderaan Universiti Teknologi MARA.
ACSON INTERNATIONAL Air Conditioner ‘Wall Mounted Split Systems’
catalogue.
‘Sistem Penyaman Udara (Jenis Berasingan)’ Polytechnic Manual book.
‘Sistem Penyaman Udara (Jenis Berpusat)’ Polytechnic Manual book.
‘Sistem Penyaman Udara’ slides from Facilities Office.
49
7.0 APPENDIX
Here is the entire appendix located.
50
