INDUSTRIAL TRAINING REPORT

AT

KAPAR ENERGY VENTURES SDN.BHD
KAPAR, SELANGOR

BY

CHOLAN A/L VENU
(ME090139)

DEPARTMENT OF MECHANICAL ENGINEERING
UNIVERSITI TENAGA NASIONAL

START DATE :09/03/15
END DATE :29/05/15

ABSTRACT

As a third year degree student in Bachelor of Mechanical Engineering (Hons.), I have been assigned to undergo industrial training for 12 weeks. This industrial training is one of the vital part of my coursework whereby I will be able to graduate from the degree programme if and only if I passed this industrial training session. Therefore, I have applied to several companies and Kapar Energy Ventures Sdn. Bhd., one of the leading companies in power plant field accepted my application as an intern. I went through a lot of challenging as well as knowledgeable working experiences throughout the industrial training period.
Therefore, I am writing this report based on my working experiences during the industrial training period. The main purpose of this report is to put down in writing the record of my training experiences. Apart from that this report is also written with the purpose of explaining my visiting supervisor about every task as well as aspects that have been assigned to me as my job scope throughout the entire industrial training period. I hope this report will serve as a summary or as an overall view for my industrial training period.
Apart from summarizing the entire industrial training experience, this report also serves as a starting point for me to train myself in effective writing as a preparation for Final
Year Project which I will undergo in upcoming semesters.

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ACKNOWLEDGEMENTS

First and foremost, I would like to express my appreciation towards the company that hired me for industrial training programme. Hereby, I am proud to say that the company that hired me for industrial training programme was Kapar Energy Ventures Sdn. Bhd.,one of the leading companies in power plant field (Refer to the Company Profile section). I am lucky to get hired under this company since I was able to undergo real-time working experiences which was quite challenging for me who was never faced such situations before.
I also would like to thank my university, Tenaga Nasional University, one of the popular private universities in Malaysia, for allowing me to undergo industrial training programme. Without permission from the university, for sure I might not go through such a great and wonderful experience.
Apart from that, I would like to grab this opportunity to thank the section members under which I have been assigned. The entire section members showed a great concern onto my working progress throughout the industrial training period. It was an honour for me to work with each of the members in the section. Special thanks to my host supervisor, Mr.
Ahmad Kamil B. Mohd Yusof for his advices which boosted me up during my down times. I really appreciate his effort to find replacement for hosting my industrial training presentation by his assistant Mr.Karim because he have attend an important meeting on that day. Not to mention, I feel so thankful to my coordinator, Pn.Zaimah Bte Hasan who provided me with proper guidance in my working progress.

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In addition to that, I prefer to express my deepest appreciation towards my visiting supervisor, Mr. Yip Chan Heng. I really appreciate his effort in attending my industrial training presentation. His effort to find out my workplace location even though he was not familiar with the Klang Valley is appreciable.
Last but not least, I would like to thank my family members and friends who provided me with great motivation during the industrial training period. Their moral support drove me throughout my working days.

SYNOPSIS
As a Third year degree student in Bachelor of Mechanical Engineering (Hons.), every student from my university requested to undergo industrial training programme for 12 week period. This was same for me since I am one of the students from the Mechanical
Engineering field. I was enrolled as an intern under one of the famous power plant named
Kapar Energy Venture Sdn.Bhd.
I have successfully gone through the industrial training programme which ended on
29 May 2015. This industrial training programmed helped me to gain unlimited experiences, knowledge as well as skills.
Therefore, I am writing this report based on my experiences when I was working under Kapar Energy Venture Sdn.Bhd. iii TABLE OF CONTENTS

Page

ABSTRACT

i

ACKNOWLEDGEMENTS

ii

SYNOPSIS

iii

TABLE OF CONTENTS

iv

1.0

INTRODUCTION

1-2

2.0

OVERVIEW OF THE TRAINING

3-9

3.0

FUNCTION OF COMPONENTS

10-21

4.0

ABOUT PROJECT

22-23

iv

5.0

DISCUSSION

24-26

6.0

CONCLUSION

27

7.0

LIST OF REFERENCES

28

INTRODUCTION
Kapar Energy Ventures Sdn. Bhd or Stesen Janaelektrik Sultan Salahuddin Abdul Aziz is a top producer of electricity in Malaysia. KEV was largest power plant in Malaysia with generating capacity of 2420MW and accommodates the electric supply for the country at about 23% to the maximum level at a time. The only power station in
Malaysia with triple fuel firing capability which (gas, coal and oil). KEV is a joint venture company between Tenaga Nasional Berhad and Malakoff Berhad with an equity holding of 60% Tenaga Nasional Berhad and 40% Malakoff Berhad. For vision of this company is to become ‘The IPP of choice Our Nations Prides’ while the company mission is ‘Prudent utilization of natural resources to generate electricity safely, continuously, effectively and efficiently for the benefit of mankind whilst preserving the environment.

Generating Facility 1(GF1)
GF1 was built in year of 1981 where these generating facilities consist of two units of operation system named as unit 1 and unit 2. The total load can be generates by GF1 was 600MW, each units generates at constant amount of 300MW at a time. The type of fuel used at this time was oil and gas. Each unit made up of 2 important parts, which is boiler and turbine. For boiler’s system, it was designed by Riley Mitsui while the turbine system was designed by Mitsubishi Heavy Industries.

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Generating Facility 2(GF2)
GF2 starts to be built in the year of 1985 where consist of unit which operates under its management namely unit 3 and unit 4. Total capacity generated by GF2 is 600MW where each unit contributes of 300MW. Fuel system used was coal, oil and gas. In this generating facility, the coal was introduced as its main fuel source.

Generating Facility 3(GF3)
GF3 is the largest facility in KEV power plant that was built in the year of 1995 where the generating facilities consist of two units named as unit5 and unit 6. Total capacity of this facility is 1000MW which each unit can generate a constant load of 500MW.
The fuel system used was oil, coal and gas. For boiler system, it was designed by IHI while the turbine system was designed by German Engineering (GE).
Referring on the training schedule given, Training Department has set me as trainee in phase 1. This is because the management want trainee to focus and make progress report only on one phase. Phase 1 constitute 2 unit namely unit1 and unit 2. Each unit generates electricity as much as 300MW. Phase 1 is the oldest phase in this power plant. Control Room GF1
Such as phase 2 and phase 3, phase 1 also has Unit Control Room (UCR) where it functions to functions to control overall operation in phase 1 by using computer system.
On the whole UCR managed 37 operations in the generating facility 1. Here employees

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who work under this unit responsible in starting the generating operation, control boiler and turbine system, study the problem by computerized or manual and the report the damage to be repaired by other unit such MECH1(expertise to repair static component) and ROMACH1(expertise to repair component which rotate).
Shift charge Engineer having responsibility in issuing permit and cancel permit in giving approval to repair the damage of component. Permit issued to state which component need to be repaired and confirmed before the work is made. This work permit aimed to ensure the safety of workers and avoid employee to open and repair components before authorized from management.

Workers in Unit Control Room (UCR) such as Senior Unit Operator (SUO) and unit
Operator (UO) will be at Unit Control Desk to monitor all system based on computer information displayed in monitor. Furthermore, both SUO and UO will identify all charges to be recorded, identify damaged component to be repaired and gives direction to patrolman to check on the area that the damage occur.

OVERVIEW of the Training
I arrived at Kapar Energy Ventures Sdn. Bhd and report to assistant training executive,
Mr.Karim. I was given the PPE (personal protective equipment) like safety helmet. I also had been remind to always wear safety boots and safety helmet in the power station area in order to ensure my safety throughout the industrial training here. The other day in the same week, I had to attend the safety briefing , organized by health department by Mr.Nagaraju at the end of this program, I had given a schedule of

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department that I had to undertrained. For the first one week, I was assigned to undertrain at the Unit Control Room of GF1.

Week 1

For this week, I was assigned to follow the Head Shift Charge of Unit Control Room
GF1, Mr. Haji Zaid. For the first day, he said that in here mostly the trainee must be able to study independently. The trainee has to frequently communicate with the unit control workers and also with the contract workers. After a short briefing, Mr Nordin the worker of the Unit Control Room takes me to the boiler site. He brought me to the boiler steam drum. Here he said to be one of the most dangerous places to be. If there is no experience, do not come here individually. He told me that this is where the wet steam was stored and then had to be released to the air. There are 3 type of generating valve that control the wet steam in the boiler steam drum, Manual Valve, Motorized
Valve. In this one week, the worker in UCR taught me the general view about boiler and turbine.

Week 2

For this week, I was assigned to undertrain with Mechanical Engineer, Mr Tamimi. He gave me a short briefing about his job scope. To be specific, he worked in the MECH1
Department, where all the static machines were inspect and maintain for the workers in

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this department. The workers in this department are very friendly. They taught me a lot about boiler properties. We have to work on the work permit given. The issued work permit determine which place or machine to be repaired such as in that week we have to service instrument HP (high pressure) compressor, cleaning the cooler box, opening hopper drain valve and so on.

Week 3

In this week the work carry out as usual like opening LP (low pressure) compressor for service, the difference between LP and HP compressor are size of LP piston bigger than
HP compressor. Housekeeping FD fan motor because excessive oil leaked from the system and saw dust is used to absorb the leaked oil. Besides that, ID fan interconnection collapse and the main hole perforated due to high pressure. We have to clean all the soot which had come out from the collapse. In this week, I had one leave for taking voucher at uniten and had a meeting with my industrial training coordinator.
The next day, I have assigned to attend safety valve testing presentation. At this presentation I have learned the mechanical function of safety valve and how they are tested. Usually they are tested in on load condition so that can obtain more accurate values to evaluate.

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Week 4

In this week, our team in MECH1 assigned to take oil sample from Force Draught fan by using special vacuum pump and send it to lab for result. This process is done to determine the life span of the gears of the system. After that, permit was issued to clean
Turbine Auxiliary Cooler Water (TACW) A. This was one of difficult task to carry out because it uses crane to carry the header plate for opening. Cleaning the soot blowers, paint them with ICI silver colour and grease them to ensure function in proper manner.
At the same week, we had open TACW A & B below part because complain received the water flow is not optimum. There are many sea muds blocking the water path at this chamber. Week 5

In this week same activities have carry out to clean Turbine Auxiliary Cooler Water
(TACW) A and followed by Boiler Auxiliary Cooler Water A. The procedure for both
Auxiliary Coolers is the same but only size of cooler is different. TACW Cooler is bigger than BACW Cooler. Oil is added to Forced Draught fan with using shell oil pumping machine. This process has to be done in running condition so that accurate level of oil is determined. The next task is replacing boiler injector nozzle due to hardened crude oil blocking the nozzle’s spray hole.

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Week 6

For the week 7, we have cleaned Turbine Auxiliary Cooler Water (TACW) B upper part and lower part with using scrapper. But this time we use different method to clean the tubes inside the cooler. By using long meatal rod according the size of tubes inside the cooler and pushed through the tubes vertically to remove the clogged dirt inside the tubes. Moreover on the same week we have replace rubber gasket on fuel oil LP
Duplex Strainer Vent Valve so that the leakage of crude oil, finally have stopped. This is my last week in MECH 1.

Week 7

I was assigned to undertrain below the Turbine Engineer Mr.Normuadzam, I order to learn more deeply about turbine system. He said that I can rather to follow him do his work or follow his workers and learn more about turbine sites. For that I chose to follow his workers because I’m more enthusiastic to learn and gain knowledge about turbine system. To be specific, this department is called ROMACH 1. My first day work was in Pump House 1.5km from the sea shore, CWP Lube water strainer box A and cleaning the strainer with tap water and iron brush. Then the next job was replacing rubbish collecting strainer box in pump house. The next day task is to carry out project in phase 2 which is doing Non Destructive Test (NDT) in boiler unit 3. The other day we changed oil to booster pump in boiler feed pump and servicing drain valve which from water storage tank.

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Week 8
We have assigned to work on Lube Oil cooler box unit 2B and unit 1B, because tube leaked is reported. The next day, we have checking Gland Steam Exhaust fan 1B valve, to make sure the fan still functioning in right manner. The next activity is adding oil to
Turbine Oil Conditioner unit 1 by using shell turbo T32 oil. About 8 drum of oil is added, each of drum contain 208 litres of oil. Lastly, cleaning the waterline in filter system at pump house due to excessive rubbish accumulated.

Week 9

We have given task to check the HP Turbine Drain Motorized Valve whether it functioning properly or not. The shaft of the valve was rusty so we smoothing the shaft using sand paper and wd-40. Introduction to Emergency Diesel Generator (EDG) function of the system is to provide electricity for the unit if any trips of the boiler. The next task is to do alignment for the Condenser Debris Filter Flushing Pump Motor. The alignment was done by using dial gauge using specific method and adding sim (small metal plate) under the motor.

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Week 10

At this week various type of task carry out, the first one is patching the condenser pipe line with Nitomortar because the pipe is perforated due to high pressure acting on it for years and corrosion. The next is changing oil seal for the main hole of condenser with using water sealant. Changing bearing for fin pump, the bearing is heated using bearing heater before install to shaft to ensure smooth installation. Servicing gear pump and install it in proper manner.

Week 11

Then the next job was replacing rubbish collecting strainer box in pump house and cleaning the water line of the filter system. This time the collecting strainer box is washed fully with using high pressure water to enable small holes from strainer is cleared from clogged. Next task was to change oil filter on boiler feed pump and fastening nut on the water storage tank valve because water leakage was reported.
Making rubber gasket for small pipe and cleaning Turbine Lube Oil cooler unit 2.
Tellus 32m industrial hydraulic oil was added to Boiler Feed Pump. Lastly, washing muds clogged inside the condenser by entering through main hole.

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Week 12

In this final week, all the trainee had been given one week time to prepare their presentations. They will be presented what had they learned during their internship at
Kapar Energy Ventures. I had so much fun in this week because the entire trainee sharing their knowledge together. At the end, I had completely achieved all the main objectives of the industrial training.

Function of components in generating operation in phase 1(Turbine Section)
Generator
A device to transform mechanical energy to electricity. Generator generates electricity when a strand of conductor carry resultant current wave when there was magnetic field cutting as a result of generator rotating. This process was called electromagnetic induction process. Generator own two major components namely stator and rotor.
Stator is part of generator that still or stationary and with coil around it. Rotor is generator part which spins to cut magnetic field in stator.
Generator rotor acts as electromagnet of variable strength when supplied with direct current from excitation system. However the generator will only function when exciter supplies direct current to rotor through carbon brush. Electric current produced from permanent magnet generator will be transformed to direct current supply by automatic voltage regulator (AVR). Direct current supply which supplied to exciter rotor winding will fully controlled by AVR traverses field circuit breaker.

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Rotor winding then converts to a huge electromagnet. When the rotor rotates, magnetic field also rotates and cut stationary stator conductor that brings to induced electromotive force (EMF). Voltage produced then fed to generator transformer. Grid frequency and voltage produced are not steady and requires adjustment at the general terminal voltage which can be done by varying generator excitation of automatic voltage regulator (AVR). AVR controls DC supply to field winding of main exciter where it determines excitation field current that need to be supplied by exciter to rotor.

Turbine
A mechanical device that used to rotate generator. When generator to rotates, it will involve energy conversion from heat energy (steam) to mechanical energy (rotor rotation from turbine). Damage used to be experienced by turbine are such as turbine blade crack, insufficient of oil bearing or excessive dirt on oil, temperature factor which could stop the turbine shaft crooked and others.

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Main parts of Turbine
A)High Pressure Turbine (HP)
High pressure turbine replaces energy in high pressure and steam temperature from HP super heater to mechanical energy to rotate generator. Super heater pressured at 166bar and temperature 538’C needed to rotate turbine at speed
3000rpm.
B)Intermediate Pressure Turbine (IP)
Received cold reheat system which been heated in reheater and turn major component. Excile steam will then through exhaust and to condenser.

C)Low Pressure Turbine (LP)
Low pressure turbine receives steam that went through crossover pipe from intermediate pressure turbine and replaces the heat energy to mechanical energy which used to rotate major generator. Exile steam will send through exhaust and to condenser.
To smooth the movement of the turbine and its equipment, there are few systems which support the turbine when it operates. Some of them are turbine lube oil system, turbine governing and protection sysytem, gland steam, turbine turning gear and exhaust hood spray. Turbine lube oil system fuctions as lubricant and protector to turbine bearing and barring gear (from aspect of the component’s movement) while turbine governing and protection system functions to control position turbine main steam valve during commencement of operations wheather the operation is manual or even during emergency. 12

As for gland steam temperature, the function is to prevent high pressured steam exited from turbine casing and to avoid outside air from entering the turbine. If outside air enters the turbine, it will harm turbine’s blades and could cause rust to the blade since air carries moisture. While barring gear is used when turbine start turning and when it stop, exhaust hood spray fuctions to maintain temperature in turbine as temperature has big influence to the turbine state.

Condenser
Condenser is the place where condensation process happen where steam molecular change to water. In condenser there where some channels of sea water tube used to cool down the steam. Space vacuum inside the condenser will attract steam from turbine rotation into condenser which then chilled or cooled by the sea water where the steam will change into water. Damage used to happen in condenser is sea water tube leaking where usually the sea water caused corrosion to the tube.

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CO2 Vaporizer
The function of CO2 vaporizer is to change the form of CO2 stored from liquid to gas.
The CO2 usually being stored in a low temperature so that it can maintain the efficiency when the CO2 gas was chosen for this purging process because we want to prevent the hydroden gas in the generator got mixed with the huge amount of air that contain heavy oxygen gas. Chemically when the hydrogen gas mixed with massive amount of oxygen,the huge explosion can be created.

Boiler section
Boiler Feed Pump
The function of the boiler feed pump is to provide water to the boiler economizer inlet and subsequenly to the boiler drum at the proper temperature and pressure. Boiler Feed
Pump capable to pump water up to 10th floor to make the water arrive at the boiler
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steam drum. The boiler feed pump normally take suction from the deaerator storage tank and discharge through the HP feedwater heaters and then to the boiler drum through the economizer. The damage usually occur at this part such as coupling oil dry, high pump strainer and others relared to it. Supply spray water to the secondary and primary super heater, reheat desuperheater,HP turbine by pass and auxiliary steam system. Consist of booster pump, motor, fluid coupling, coupling and boiler feed pump.
Activity carry out, changing oil filter to boiler feed pump, so that it can filter dirt and iron erosion from the gears due to tear and wear. Futhermore, adding oil to fluid coupling machine within boiler feed pump using Tellus 32m industrial hydraulic fluid

Economizer
Economizer is the last heater for water (last stage of reheat) before it arrived at the boiler steam drum. The economizer will function by using (utilizing) scorching heat inside flue gas bofore it been released to the chimney. The temperature of the water supply can be increased about 40’C to 50’C which can short the time period for the
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water to change form from liquid to gas. The damaged that usually occur at this place were pipeline breach, safety valve malfunction and others that related to it.

FEEDWATER SYSTEM
The main function of the feedwater system is to supply feedwater to the boiler economizer. The Dearetor Recirculation Pump is used during start-up to circulate feedwater from the deaerator storage outlet back to the deaerator inlet in order to promote deaeration and more uniform heating of feedwater.

LUBE OIL COOLER
The function of the lube oil cooler is to reduce the temperature of lube oil discharge from the oil pumps and ejects before it flows to the turbine and generator bearings.
There are two lube oil coolers, one is normally in service and the other one is on standby. Seawater from circulating water system enters the top of the coolers, flows downward through the cooling tubes and reverses direction at the bottom of the coolers.
The seawater then flows through the other side of the tubes back to the top of the coolers and exits to the CW return header.

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Boiler Steam Drum
Boiler steam drum received feedwater from the economizer and distribute the water to the furnace. Boiler steam drum also received wet steam from the wall tubes. The equipments in the drum can separate the water mixtures and the steam. So some of the wet steam been sent back to the reheater to obtain dry staem that can be used to rotate the turbine blade and some of the wet steam were released to the atmosphere.

Debris Filter
Four debris filter are provided. One each for shell 1A side 1, shell 1A side 2, shell 1B side 1 and shell 1B side 2. The debris filters are installed upstream of the condenser tubes. The filters remove any debris carried with the inlet seawater, and prevent fouling of the condenser tubes. The debris collected by the filters is discharged downstream of the condenser. A debris filter consist of a cone shaped filter screen, and evacuation

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rotor, drive unit, debris discharge valve, two pressures sensing ports with hand operated isolating valves, a differential pressure sensing unit and automatic filter bypass.

Forced Draft Fans (FD FAN)
The twoforced draft fans provide all the air required for complete combustion of the fuel in the furnace and force the resultant flue gas through the boiler, steam air heaters, gas air heaters and the electrostatic precipitators to the chimney. The FD fans also provide supply air to the primary air fans. The FD fans discharges its output through a steam air heater (SAH) to the secondary air inlet side of a trisector regenerative air preheater or gas heater (GAH). From GAH the hot combustion air enters the furnace through windboxes. Activity carry out, taking oil sample for lab result to determine the life span of the internal gears, adding oil to FD fan with shell industrial lubricating oil using oil pumping machine. This process has to carry out with machine running condition because then only accurate volume of the oil needed can be determined.

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INDUCED DRAFT FANS (ID FAN)
The induced draft fans maintain the furnace pressure slightly below atmospheric pressure by drawing flue gas through the boiler, the gas air heater and the precipitators.
The ID fans take suction from the precipitator outlet and discharge flue gas through the stack. Problem that occured, ID fan interconnection collapse and the main hole perforated due to high pressure band heat. We have grind the riveted plate to open the interconnection path and clean the soots escaped from the collapse path.

BURNING INJECTION
This place where the fuel will be injected into the furnace. The injections of the fuel must follow the stages given in the manual so that they can increase the efficiency to get complete combustion in the furnace. It is almost possible to get complete combustion due to many interrupt manners during the combustion process. Task carry out, replacing boiler injector nozzle due to hardened crude oil blocking the nozzle’s spray hole, this nozzle function is to spray crude oil in a specific pressure in order to achive complete combustion. Servicing injector nozzle by using kerosene so that hardened crude can be easily remove with help of iron brush.

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Instrument Air system
The function of the system is to provide clean air to various form of instrumentation and controllers through the plant at 8bar. The air is drawn from atmosphere through a silencer and a filter. The airis compressed in two stages reciprocating compressor equipped witn an air intercooler between stages. The cooled compressed air exiting the intercooler enters the HP stage compressor and discharges through the shell and tube after cooler. The compressed air then flowa through a moisture separator and into a common compressor discharge header.

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BACW COOLERS
The function of BACW cooler is to reduce the temperature of the boiler auxiliary cooling water by using water. Two vertical shell and tube coolers are installed in the
BACW system. Under normal condition, one cooler is in service while the other is on standby. Each cooler is one pass heat exchanger and has two water boxes, one on top and one at the bottom of the cooler. 1782 cooling tubes giving a cooling run vertically from the top to bottom water box.

TACW COOLERS
The function of the TACW cooler is reduce the temperature of turbine auxiliary coolongwater by using seawater. Two vertical shell and tube coolers are installed in the
TACW system. Under normal operation, one cooler is in service while other is on standby. Each cooler is a two passes heat exchanger and has water boxes, on topn and one at the bottom of the cooler. The top water box is divided into two sectionx, one
21

section for the seawater inle and the other for the seawater outlet. 1404 cooling tubes run vertically from the top to borrom water boxes.

About project
Given task to work with contractator to carry out non destruction test (NDT) on boiler in phase 2. We enter the boiler from top main hole, there are already contractor working inside assembling scaffolding towards the boiler tubes from below to top of the boiler.
This test is carry out once a year to determine the thickness of the boiler tubes inside boiler. First they are some procedure to follow before entering the boiler. They are wearing full covered suit, safety glasses, mask and a personal torch light. This is because the condition inside the boiler were so dusty due to ash produced from coal combustion for the boiler.
The test is carry out by using ultrasound transmitting device looks like big voltage meter. This test has to be carry out in one condition which is the surface of boiler tubes must me clean, so that accurate reading can be obtain. The contractor divides works among us, they are two teams, each team cosist of four people which means one people
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have to clean the surface of boiler tubes using iron brush, one people have to put coplant (a solution which act as a medium for ultrasound reflection between boiler tubes and the device), one people handling the ultrasound transmitting device and one person write down the reading shown. Only one boiler tubes are tested in the row of boiler tubes.
Problem encountered is difficult to clean the surface of boiler tubes, the ash sticked through out the tubes like cement and walking in the scaffolding was very dangerous.
We have to climb down using scaffholding stairs seven stories below to finish the task.
The thickness of the boiler tubes should be 6.5mm originally but in our data its only shows 5.8mm this because the boiler tubers corroded due to the friction between steam and surface of boiler tubes. Finally the life time has to be calculated using a specific formula using the mean value of the data taken.

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DISCUSSION
Safety at work place
Workplace safety and health is immensely important for the every reason improving productivity. It is only when the employees feel safe at work that they can invest th fullest of their capacities and exploit the best of their pontential to work. Heavy industries may be a great place to work and earn big salaries however with the speeds in which events occur mixed with the sum of possible safety hazards, it might be our grave. Danger are elsewhere in the site oh heavy industries. Dangers could come from our own negligence, others negligence or the condition of the site itself. It can be avoided if all site hazards are well avoided and safety precautions are seriously taken.
These are the most important hazard recorded in industry:

A) Trip and fall
Falls from equipment, scaffolding and other high places are dangerous and far too common to occur.

B) Scaffolding
This also causes falls and if put together improperly can cause injuries and death. People seldom think about heavy industrial equipment safety with respect to equipment that moves but standstill equipment can be just as dangerous when not used properly.

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C) Electrical Appliances
This hazard involves all the electrical appliances used seldom in site. Explosion electrical shock or electrocution may occur on these appliances if not well maintenance. If this occurs serious injury and fatality may occur. To prevent this from occur in their workplace continuous inspection need to be executed to all electrical appliances used in their site.

D) Over-exertion and stress
This respectively use injury has been recorded as the fastest growing type of injury in the workplace. It is caused by repeating the same action or maintaining the same position for a long time. The effects of this problem are unconscious and injuries at wrist hand or back.

E) Excessive Noise
Most of heavy industries workers are exposed to excessive noise that comes from operating machines. The louder the noise can produce more damages. The excessive noise may cause permanent injury like hearing loss either progressively, or by the exposures over a long period of time. To prevent these problem workers need to wear ear buds when working in a noise site.

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PERSONAL PROTECTIVE EQUIPMENT (PPE)
PPE is defined as equipment which is intended to be worn or held by a person at work and it protects him against one or more risks to his health or safety. Employers have basic duties concerning the provision and use of personal protective equipment at work and they have no rights to ask for money from the employee for that equipment, whether it is returnable or not. If employment has been terminated and the employeekeeps the PPE without any permission, as long as it has been made clear in the contract, the employer may be able to deduct the cost of placement from any wages own. Environmental Issue
For Kapar Power Station, they keep believe that they will only suceed in the long term if their actions respect the common interest. This means they must not comply with laws but also conduct buisness consistent with sustainable development principles.
Thus ,they are commited to the protection of the environment, human health and wellbeing, to the migration of climate change and the conservation of nature. With objective of to ensure the continued improvement of environmental performance, they aim to use energy and natural resources more efficiently, minimize the production of waste, harmful air emissions, and water discharge while seeking ways to preserve landscape and biological diversity.

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CONCLUSION

In a nutshell, this industrial training programme was a useful experience for me.
I have gained plenty of things in terms of new knowledge, skills and met many new people. I achieved several of my learning goals which hopefully will be extra points for me in my upcoming studies.
Throughout the entire industrial training programme, I have majorly trained myself to be more responsible onto the task that have been assigned to me. Another main thing that I have learned from this industrial training programme is time management. When I first started with my industrial programme, I was thinking that I wouldn’t be able to make myself to manage multiple tasks at one time. However, this condition turned apart slowly when I was started to train myself in managing time efficiently. I took some initiative by observing the way my colleagues work and applying the same to my work life. This condition enabled me to accomplish the tasks on time and at the same time developed confidence within myself day by day.
Apart from time management and responsibility skills, I have also learned to be more independent in work. I tried to learn things that are necessary for my work by myself even though this condition delayed my learning process. Furthermore, I also learned to be more flexible throughout the industrial training programme.
As a whole, I can conclude that I enjoyed to work under Kapar Energy Ventures
Sdn. Bhd. It was a great honour for me to get enrolled under one of the biggest power plant in Malaysia. Hopefully, the experiences and knowledge that I have gained throughout the industrial training programme will lead me to a brighter future life. This was a great journey for me and I hope other interns from different companies got as much as I did.

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REFERENCES
Books
1. Power plant engineering. Published by A. K. Raja, Amit Prakash Srivastava.
2. Tonry. 1961. Heat Transfer System for Dry Process Kilns in Electricity
Manufacturing. Published by Pit & Quarry. Chiacago (p.151-154).
3. 1983. Pulse Energization of Electrostatic Precipitator. Copenhagen:Denmark.
4. The On Job Training procedures at Unit Control Room.
5. Documents related to Power Plant in Kapar Energy Ventures resoures centre.

Websites:
1. http://books.google.com.my/books/about/Power_Plant_Engineering.html?id=p7km_VZqxc&redir_esc=y
2. http://en.wikipedia.org/wiki/Power_station
3. http://science.howstuffworks.com/environmental/energy/power.htm
4. http://www1.eere.energy.gov/geothermal/powerplants.html
5. http://www.nrel.gov/csp/throughnet/power_plant_systems.html
6. http://www.brownmarine.com/powe_plants.htm
7. http://www.kaparenergy.com.my/index.php/special-interest

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