Photo shoot september 2012

55w light power for free

Refer to picture below, this cheepest technology just using used coke plastic bottel and fill up full with water and attach on your house roof, with the reflect from sunlight it will produce reflect equel to 55w lighy brightness.

Try it.

Dont foget to seal the joiny area to prevent rain water leak.

Photo shoot august 2012

2nd gread steam engineer oral questions.

12011 2nd grad steam engineer oral questions.

11.       What is your roles and responsible as Assistant Engineer in your work place.

  To ensure smoothness of process, workers safety, Preventive maintenance and ensure all   machinery are safe to be used.

22.       What is the Objective of you to take this exam?

  At my work place there is 3 unit boiler, with total Heating surface connected to common range  6,189sFt but we only operate single boiler, according to FMA person in charge reg 5, it require 2^nd grad steam engineer.

33.       Name the ACT that related to JKKP?

  FMA 1967 ACT 139, OSHA ACT 514 1994.

44.    Name the regulation on FMA related to steam boiler?

  Steam Boiler & Unfired pressure vessel, Person In Charge, Certificates of Competency &  Notification, certificate of Fitness & Inspection.

55.    List Down 13 esiantel Fittings for steam boiler?

a)      Describe more about safety valve.

                                                        i.            Must be adjusted to open at ASWP or before ASWP.

                                                      ii.            Area of such valve sufficient, max. Blow P raised below 10% of ASWP.

                                                    iii.            If H.Surface below 30s ft, valve D min is ¾”, if H.S above 30s ft, valve min d is 1”.

                                                     iv.            Discharge bust be free flow.

                                                       v.            Valve adjustment must be sealed.

                                                     vi.            Spring length without load must be below or same 4X spring OD.

                                                   vii.            When in compression, spring high must not less  than ¼ x valve D.

b)      Why does superheater Safety valve must blow 1^st than follows by steam drum?

No. Steam drum S.Valve must blow first in order to prevent steam starvation.

c)       Practical test on water gauge glass testing?

d)      What is the size of the gauge glass at your Boiler?

e)      What is the P your gauge glass can sustain?

f)       How do you test low water alarm?

By shutting lower cock at water column attached on low water alarm instrument (Mobery) alarm should sound.

66.       What type are this boiler?

Wet beck marine scotch boiler

77.       What is the name of the furnace?

Corrugated Furnace.

88.      Sketch a steam boiler including, tubes and header(name each tube), hot gas flow and buffet.

Down comer, superheater tube, generating tube, Distributing  tube & Economizer Tube.

99.       How many pass?

3 pass

110.   What is the ASWP of your Boiler?

25 bars

111.   From where does ASWP generated from?

Boiler manufacturer.

112.   Explain about Emergency situation on steam boiler?

a)      Tube bust?

Continues pump water to steam drum in order to maintain water level and light off the fire at furnace, shut down all fans last is ID fan, remove all fuel in furnace, let boiler cool down by opening furnace door, inspection door, lastly inform JKKP.

b)      Low water level?

Stop pump water in to steam drum to prevent thermal shock, stop adding fuel, shut down all fanes lastly is ID fan, let boiler cool down, Inform JKKP.

113.   Explain about internal water treatment?

Explain water treatment at boiler treatment from water softener to steam boiler, softener to discharge calcium n magnesium (remove hardness), vacuum dearator to remove oxygen; can cause corrosion at boiler, and list down boiler water quality. Chemical Dosing to react residual Hardness (Prevent scale), Anti foam (Prevent carry over), Sulphite (prevent corrosion), Phosphate & Caustic (increase PH and prevent Scale), sludge con. (Prevent sliding metal).

Useful tips.

(a)    Inspector will be very happy if answer are follow up with sketch of drawing.

Basic Function Of Each Station (Palm Oil Mill)

Reception Station

The function of this station is, receiving and storage of FFB brought from the estate, in Lorries, to Mill and delivery of FFB to process.

Sterilization Station

To inactive the enzymes that promote the formation of Free Fatty Acid.
To make easy the fruits loosen from the bunch.
To break oil cells in the mesocarp so that oil recovery is easier.
To minimize water content in the fruits.

Stripping / Threshing Station

For separation of the fruits from the bunch using the rotary drum.

Pressing Station

For extraction of oil and nut of kernel. This station consists of Digester unit, Screw Press unit and Conveying Equipments.

Clarification Station

For separation of crude oil and sludge to make pure oil

Kernel Recovery Station

For nut processing to recover Kernels
This station can be divided into three process, i.e. : Depericarper, Nut Cracking and Kernel Drying.
Depericarper for separating Fibre and Nut.
Nut Cracking for separation of kernel and shell..

Sizing of Clarification Tank

Sizing Clarification tank

Mill capacity,                                     C_m1      :           40 MT/ hr

Diluted crude oil to FFB,                 n          :           65 %

Diluted Crude oil,                             T_CO      =          C_m1 x n

                                                                        =          40 x 0.65

                                                                        =          26 MT/ hr

Retention time,                                 RT       :           6 hours

Safety factor,                                     k          :           1.2

Capacity of clarification tank                     =          T_CO x RT x k

                                                                        =          26 x 6 x 1.2

                                                                        =          187.2 MT

                                                                        ~          190 MT

Assume

                        Empty space,            A         :           1 ft (0.33m)

                        Oil Layer                    B         :           1 ft (0.33m)

                        Sludge Layer                        C         :           distance of oil droplets travel

Oil particle size & %             :           90 % > 60 micron

                                                                        :           10 % < 60 micron

According to Stork’s Law                           

Velocity of rise,         v          :           125 micron/ sec

Retention time,         RT       :           6 hrs

Distance of travel, c             =          v x RT

                                                =          125 x 6 x 3600

                                                =          2700 mm

Total length of clarifier feed pipe              =          A + B + C

                                                                        =          (0.33) + (0.33) + (2.7)

                                                                        =          3.36 m

Height of clarifier tank,                    H         =          2 x 3.36

                                                                        =          6.8 m

Diameter of clarifier                         D         =        

                                                =          6.2 m

Palm oil mill cost saving.

1. Maximize insurance claim, know well on insurance policy coverage.
2. Capitalise major equipment annual service such as boiler, decanter and steam turbine.
3. Implement preventive maintenance.
4. Maximize wear and tare parts such as pump component, conveyor liners and cyclones but ensure parts are available at store.
5. Recycle materials from scrap iron such as cages body, sterilizer linear, press main shaft and conveyor drive shaft.
6. Cary own motor rewinding for power below 3kw.
7. Use standard equipment such as pump, conveyors and press this will bring down stock value.
8. Reduce diesel consumption by running steam boiler and advantage for mill with EFB press and shredders.
9. Declare SER ( shell extraction rate).
10. Use on CPO and pk vehicle for dispatch.
11. Proper labor utilization.
12. Reduce outsource maintenance but provide allowance for own maintenance team for project.
13. Don't paint any s.s pipe or tank but polish it to shine.

use hot water at hydrocyclone

Most all oil mill are using cold water for hydrocyclone operation.
Recently we had try to use hot water with 80d c for hydrocyclone. Water source are from turbine cooling water, decanter flushing water and vacuum drier, all of the water been pump to hot water tank and use as press dilution and if hot water tank are full it will overflow to hydrocyclone.

The advantage are we able to reduce kernel silo drying retention time. PK moisture exit hydrocyclone are only 10% compare using cold water are 19%.

 Which means only less energy are required to further dry it.
In terms of PK loss in hydrocyclone it still remain same.

Hari raya 2012

For this year we able to stop processing at 1800hrs 1 day before raya, thanks to all staff and workers for showing commitment and responsibility.

With proper planing this year we able to clear all crop early. Selamat hari raya to all.

Legal requiment for palm oil mill

1. Occupational safety and health act 1994.
2. safety & health committee reg 1996.
3. Safety & health officer reg 1997.
4. Classification, packaging and labeling of     hazardous chemical reg 1997.
5. Use & standard of exposure of chemical hazardous to health reg 2000.
6. OSH NADOPOD.
7. Factories & machinery 1967.
8. Safety, health & walfare.
9. Person in charge reg 1970
10. Notification, certificate of fitness & inspection. Reg 1970 amended 2004.
11. Steam boiler & unfired pressure vessel reg 1970.
12. Electric passenger & goods lift 1970.
13. Noise exposure reg 1989.
14. Fencing of machinery & safety reg 1970.
15. Certificate of competency & examinations.
16. Uniform building by laws 1986.
17. Garis panduan pendaftaran penyelia keselamatan tapak binan 2011.
18. Poisons Act 1952 act 366.
19. Electrical supply act 1990.
20. Petroleum (safety measures) act 1984
21. Local goverment act 1976.
22. Fire services act 1988.
23. Fire certificate reg 2001.
24. Environmental quality act 1974.
25. Industrial effluent reg 2009.
26. Sewerage services act 1993.
27. Clean air reg 1978.
28. Control of emission from diesel engines reg 1996.
29. Refrigerant management reg 1999.
30. Scheduled waste reg 2005.
31. Halo management reg 1999.
32. Guidelines for desludging for palm oil and rubber mills.
33. Sabah labour ordinan.

E book for sale

1. Project 1 (A Feasibility Study of Using Auto Dilution System for Palm Oil
    Mill & Dilution Control). RM 50, in PDF Format.

2. Project 2 (POTENTIAL AIR CONTROL TECHNOLOGIES FOR
    PARTICULATE REDUCTION FOR PALM OIL MILL WASTE
    FIRED BOILER.). RM 50, in PDF Format.

How to reduce press fibre oil loss.

Limit set for press fibre oil loss are below 3.5 OLWB. Actualy the process of reducing oil loss in press fibre start from sterilizing and digestion.

But for now i only will cover on digester and press.

1. Ensure digester bottom plate are functioning well. Try to use 6-8mm holes. Taped holes will easily choke. Total area of perforated holes shall more than 14,000 mm square.

2. Sufficient area of pipe size to harvest oil from bottom plate, use 2 point of 4" pipes as per photo.

3. Tape 1" steam line before digester insulating steam valve to bottom plate pipe and shut bottom plate pipe valve to clean perforateds holes using steam.

4. If bottom plate are working well, digester amps shall be 45-50. If less it indicates digester are lubed.

5. Apply only 35-40bar for press cone pressure to prevent high broken kernel.

6. Digester side drainage at digester chute must work well.

5. Tape 1" pipe at top of digester discharge chute, use hot water with 90dc to flush oil from fibre and it will flow to side drainage.

6. Mantain clearance of digester arms at 2" to digester linear.

7. Digester redanden angle bar must work well to have proper digestion.

8. Ensure press cages consist of 19,000 or more holes.

9. Digester level mantain at 3/4 full and been feed continuesly.

10. Right instalation and rotation of digester arms.

After implimented all as above press worm screw can be mantained up to 1,300 hrs.

Minister visit 23.7.2012

Tan Sri Bernard Dompok, Menteri Perusahaan Perladangan dan Komoditi (KPPK) Malaysia melawat Plantations Genting Berhad (GENP) Trushidup kilang kelapa sawit di daerah Kinabatangan, yang berdekatan dengan Sandakan, Sabah pada hari Isnin (lihat laporan berita di bawah).

Tan Sri Bernard, yang mengetuai delegasi 40 orang, menghabiskan masa lebih 3 jam di Kilang Minyak Trushidup Genting. Beliau telah diiringi oleh pegawai-pegawai kanan dari Lembaga Minyak Sawit Malaysia (MPOB), yang diketuai oleh Pengerusinya Tan Sri Shahril Abdul Samad dan Ketua Pengarah Datuk Dr Choo Yuen May.

Lain-lain pelawat terkemuka ialah Dato 'Lee Yeow Chor, pengerusi Majlis Minyak Sawit Malaysia; Dato' Mamat Salleh, Ketua Pegawai Eksekutif Persatuan Minyak Sawit Malaysia; dan Dr. Laurentius Ambu, Pengarah Jabatan Hidupan Liar Sabah.

Kontinjen Akhbar, yang terdiri daripada wartawan-wartawan dari akhbar-akhbar utama dan stesen TV juga turut hadir.

Perjalanan Menteri adalah sebahagian daripada lawatan dua hari ke Hilir Sungai Kinabatangan, dan dataran banjir, hidupan liar di Borneo dan semua Malaysia, termasuk burung kenyalang, monyet bangkatan, orang utan dan gajah pygmy.

Lawatan Tan Sri Bernard untuk kilang minyak Trushidup Genting adalah untuk melihat, industri-sistem biologi pertaman dan proses yang digunakan oleh Genting Plantations Berhad (GENP) untuk merawat buangan kilang minyak sawit (POME) yang terkemuka. Beliau telah mendengar bahawa jurutera pemprosesan GENP, diketuai oleh Choo Huan Boon, Snr. VP, Pemprosesan, telah dapat membawa permintaan oksigen biokimia (BOD) kepekatan POME dirawat kepada kurang daripada 20 bahagian per juta (ppm).

Permintaan oksigen biokimia atau BOD adalah jumlah oksigen terlarut yang diperlukan oleh organisma aerobik biologi di dalam air untuk memecahkan bahan organik. Ia digunakan secara meluas sebagai penunjuk kualiti air organik.

Di Semenanjung Malaysia, Jabatan Alam Sekitar (JAS) telah menetapkan tahap pelepasan yang dibenarkan pada 100 ppm. Standard yang lebih tinggi di Malaysia Timur: 50ppm di Sabah.

Sebagai perbandingan, mentah, POME yang tidak dirawat adalah 25000 ppm BOD.

Tan Sri Bernard dan VIP 40-plus terkejut mengetahui bahawa sesungguhnya, Trushidup Genting Oil Mill telah mampu untuk secara konsisten mencapai pelepasan POME kurang daripada 20 ppm BOD. Mereka juga melihat bahawa air yang telah dirawat ini kemudiannya diguna semula, untuk tujuan permohonan tanah, kembali di Kawasan Sekong Genting.

VIP seperti terkejut mendapati bahawa Trushidup Genting Kilang Minyak yang dirawat kolam POME kini telah menjadi rumah untuk burung hijrah dan hidupan liar. Mereka juga kagum dengan inisiatif kemampanan GENP.

Pengerusi MPOB, Tan Sri Shahril, mengatakan bahawa GENP perlu publisiti kerja baik yang dilakukan di Genting Minyak Trushidup Kilang untuk merawat POME.

Dengan jelas, pengurus kanan minyak kilang , Tn. Haji Mokhtar Hashim, dan pasukan jurutera, telah menjalankan tugas dengan cemerlang. Mokhtar juga pengerusi Meja Bulat pengisar pada pasukan Minyak Sawit Lestari (RSPO). Hakikat bahawa Kilang Minyak Trushidup Genting mempunyai Pertubuhan RSPO juga dilihat  Tan Sri Shahril.

Usaha kemampanan GENP, diketuai oleh Chew Jit Seng, Naib Presiden, Kelestarian, juga datang untuk memuji. Pada hari Selasa, Tan Sri Bernard dan rombongannya membawa lawatan jam lama untuk Harta Tanjung Genting dan Sanctuary Baha, projek penanaman pokok berhampiran sungai-sungai yang dimulakan pada tahun 1999 dengan WWF dan Jabatan Hidupan Liar Sabah.

GENP telah diketepikan 86,48 hektar tanahnya sebagai hutan Nilai Pemeliharaan Tinggi dan telah ditanam 26.000 spesies pokok asli.

Satu sarang orang, utan bersama-sama dengan 3 dewasa orang utan telah dikesan dalam Sanktuari Baha. Dan awal minggu ini, orang utan yang muda telah ditangkap oleh Jabatan Hidupan Liar Sabah. Ia tidak lama lagi akan dilepaskan ke tempat perlindungan yang lebih besar. Orang utan perlu hutan sekurang-kurangnya 100 hektar untuk berkembang maju.

Photos:

1. Tan Sri Bernard dan VIP mengagumi Genting indah Trushidup Kilang Minyak kolam dirawat POME, yang menawarkan liar, burung hijrah, hidupan liar;

2. Tan Sri Bernard di Genting Trushidup pejabat Kilang, mempengerusikan sidang akhbar;

3 & 4. Baris botol yang mengandungi POME mentah dan POME dirawat, berbanding air minuman, yang mempunyai 5 ppm BOD.

Dari The Star:
Rabu, 25 Julai, 2012;

Perniagaan »

Harga minyak sawit kekal tinggi

Perusahaan Perladangan dan Komoditi Menteri Tan Sri Bernard Dompok melihat harga yang kukuh bagi komoditi itu dalam tempoh lima bulan akan datang.

Firma penyelidikan telah menganggarkan purata minyak mentah sawit (MSM) bagi tahun ini berlegar antara RM3, 100 dan RM3, 500 satu tan.

SANDAKAN: Harga minyak sawit kekal tinggi dalam tempoh lima bulan akan datang disebabkan cuaca merosakkan tanaman di Amerika Syarikat, dua kali ganda India cukai ke atas produk ditapis dan El Nino menghampiri fenomena.

Dalam menjanjikan harapan cerah bagi komoditi itu, Menteri Perusahaan Perladangan dan Komoditi Tan Sri Bernard Dompok berkata: "Saya tidak nampak apa-apa bencana yang datang cara kita.

"Harga adalah lebih tinggi sekarang dan jika kemarau AS terus seperti yang diharapkan, maka akan lebih banyak permintaan bagi minyak sawit dan harga akan naik," katanya kepada pemberita selepas lawatan ke Kilang Minyak Sawit Trushidup.

Kacang soya dan harga jagung mencecah rekod tertinggi baru Jumaat, diberi kemarau putus-putus di Amerika Syarikat yang mengurangkan bekalan minyak kacang soya, yang dijangka untuk menaikkan harga minyak masak dan minyak sawit mentah (MSM) akan mendapat manfaat daripada kenaikan.

Minggu lepas, India, pengimport minyak terbesar di dunia yang boleh dimakan terutamanya membeli minyak sawit dari Malaysia dan Indonesia, menarik balik pembekuan enam tahun pada harga import asas minyak sawit olein bertapis.

Harga minyak sawit dijangka meningkat berikutan langkah India dan pengeksport Malaysia akan mendapat manfaat sebagai eksport minyak sawit dari Indonesia mungkin jatuh.

Firma penyelidikan telah dianggarkan harga purata MSM bagi tahun ini berlegar antara RM3, 100 dan RM3, 500 satu tan.

Sementara itu, pada banyak bercakap tentang pencemaran di Sungai Kinabatangan di Sabah dan di Sarawak, dengan kelapa sawit pelepasan efluen kilang sawit (POME) sebagai salah satu punca, Dompok berkata kerajaan dan Lembaga Minyak Sawit Malaysia (MPOB) telah secara aktif menilai kapasiti kilang yang sedia ada untuk mencapai 20 bahagian per juta (ppm) Permintaan Oksigen Biologi (BOD) secara konsisten.

Bagi Malaysia secara amnya, had BOD untuk keluar ke padang air ialah 100 ppm.

Walau bagaimanapun, di Sabah, Sarawak dan di kawasan sensitif alam, syarat-syarat yang lebih ketat telah dikenakan. Bagi kilang-kilang kelapa sawit baru, keperluan 20 ppm BOD, ditambah pula dengan pengairan tanah, telah dikenakan di Sabah.

Dompok berkata, kualiti air sungai tidak akan terjejas.

Terdapat 428 buah kilang minyak sawit di negara ini, yang mana, 124 kilang ini adalah di Sabah, menjadikan negeri pengeluar terbesar MSM di Malaysia.

"MPOB, Persatuan Minyak Sawit Malaysia dan Jabatan Alam Sekitar bekerja rapat untuk memastikan kilang merawat POME ke tahap BOD yang terendah.

"Mereka harus menjalankan penilaian terhadap loji rawatan sedia ada untuk memastikan keupayaan mereka untuk sentiasa memenuhi keperluan 20ppm.

"Jika semua pihak yang berkepentingan bekerjasama, isu POME boleh ditangani secara berkesan untuk memastikan kemampanan industri," katanya. - Bernama