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INDUSTRIAL TRAINING REPORT

PETRONAS LUBRICANT INTERNATIONAL


SDN.BHD MELAKA LUBE BLENDING
PLANT

NUR AFFIQAH BINTI ZULKEFLEY

REPORT SUBMITTED IN PARTIAL FULFILMENT


FOR THE BACHELOR OF ENGINEERING WITH
HONOURS
(MECHANICAL)

UNIVERSITI KUALA LUMPUR INTERNATIONAL COLLEGE


2016
DECLARATION

I declare that all parts of this report are the result of my own work except for the

quotations and references, the sources of which have been acknowledged in the

bibliography.

2016 NUR AFFIQAH BINTI ZULKEFLEY

ii
This report was read and verified by:

……………………………… ………………
(HARMIE AZRAK BIN MAAT) Date
Company Supervisor

……………………………… ………………..
(MAHFODZAH MD PADZI) Date
University Supervisor

iii
ACKNOWLEDGEMENT

The trainee is very thankful for such an inspirational and prolific period spent

throughout her internship with PETRONAS LUBRICANTS INTERNATIONAL

SDN BHD, MELAKA LUBE BLENDING PLANT. Being here, it thought her so

much about lubricants and industrial situation.

First of all, the trainee would like to deliver special thanks to Mr. Syed

Zulkhiriee bin Syed Hussin, the Production Manager for the opportunity and

entrusting her on being a helpful hand in completion of projects that falls under

production areas. Other than that, the trainee would also like to thank Mr. Harmie

Azrak bin Maat, production supervisor for his patience and guidance towards other

given task and experience earned throughout her industrial training period. Yet we

are dealing with different projects he is always there to share his knowledge and

experiences with the trainee. He has been very inspiring towards completing her

Industrial Training (InTra). It is indeed very lucky to be placed under his supervision

as he guide and assist her during the internship period thus making her more reliable

for industry that she about to involve with.

Aside from that the trainee also wants to show her gratitude to Mr. Hussin

PLI’s base oil supervisor for teaching her and always be a good support in the

inventory. He never fails to support while doing her task. He is also a very kind,

friendly and down to earth person. Every knowledge that he has he will share with

her without any hesitant. Yet the trainee feels very great and comfortable working

with him.

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Next, I would like to thank the University Supervisor from Universiti Kuala

Lumpur International College, Madam Mahfodzah Md Padzi for scheduling her

valued time to pay visit. Finally, the trainee would like to offer her gratitude towards

her beloved university, Universiti Kuala Lumpur International College, for letting

her to undergo industrial training and thus improving her knowledge obtained and

the opportunity to apply it in future career.

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ABSTRACT

The report is divided into two sections; the economic section and the technical

section. The economic section contains the company profile of PETRONAS

LUBRICANT INTERNATIONAL SDN.BHD (PLISB) which is recognized as one

of PETRONAS’s owned subsidiary, the leading national oil corporation. PLI mainly

consist of two giant lubrication liquid companies, FL Selenia and PETRONAS’s own

Lubricant Unit. There are various types of products produced at the Melaka Lube

Blending Plant. The products vary according to the type of raw material received,

and the difference in packaging the finished goods. Its product is marketed locally

and worldwide. In the technical section, the trainee was given a number of tasks

which mostly involve in documentation such as Operation Procedure and Overall

Equipment Efficiency. All the task given were completed and were gathered into this

report.

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TABLE OF CONTENTS

DECLARATION ii
ACKNOWLEDGEMENT iv
ABSTRACT vii
LIST OF ILLUSTRATION viii
LIST OF APPENDICES ix
GLOSSARY OF TERMS USED x
CHAPTER I
INTRODUCTION 1
CHAPTER II
GENERAL OVERVIEW OF PETRONAS LUBRICANT 3
INTERNATIONAL
- History of PLI 4
- Corporate profile and Core business 7
- Corporate Logo 10
- Vision and Mission 10
- Types of Product 11
- Types of Services 17
CHAPTER III
ASSIGNMENTS, GENERAL TASK AND WORK EXPERIENCE IN 19
MLBP
- Operation Procedure 20
- Overall Equipment Efficiency 22
- Base Oil Transfeering from Vessel 22
- Sampling 24
- Dipping 25
CHAPTER V
CONCLUSION AND RECOMMENDATION 26
REFFERENCES 28

vii
LIST OF ILLUSTRATION

2.1 Organization Chart of MLBP 9


2.2 Corporate Logo of PETRONAS 10
2.3 Raw Material Receiving Process 11
2.4 Raw Material Receiving Process 11
2.5 Blending and Filling of Lubricant 12
3.1 Operation Procedure 19
3.2 Daily OEE Data 20
3.3 Hose Moving from Tg. Bruas Tank to Vessel 21
3.4 Connection of hose from Jetty to Vessel Manifold 21
3.5 Sampling from Drum 22
3.6 Sampling from Tank 22
3.7 Tank Dipping Process 23

viii
LIST OF APPENDICES

REFERENCES 26
APPENDIX A 27
APPENDIX B 28
APPENDIX C 29
APPENDIX D 30
APPENDIX E 34
APPENDIX F 36
APPENDIX G 37

ix
GLOSSARY OF TERMS USED

UniKL ICOLE Universiti Kuala Lumpur International


College

InTra Industrial Training

PLISB Petronas Lubricant International Sedirian


Berhad

MLBP Melaka Lube Blending Plant

Tg. Bruas Tanjung Bruas

OP Operation Procedure

OEE Overall Equipment Efficiency

HSE Health, Safety and Environmental

ISGOTT International Safety Guide for Oil


Tankers and Terminals

COQ Certificate of Quality

x
CHAPTER I

INTRODUCTION

Universiti Kuala Lumpur International College (UniKL ICOLE) was

established with the aim to yield diverse graduates who are dominantly

competent and possess traits such as critical thinking, daily learning capability,

communication and communicative expertise, corporate insight, practicality and

as well as developing solution synthesis skill. The Student Industrial Training

Program (InTra) was structured by UniKL ICOLE is an obligatory training

program where undergraduates should experience industrial training work for 10

weeks prior to their graduation qualification.

The main objective of InTra is to expose UniKL ICOLE students to the

real working environment in order to relate theoretical knowledge and applying it

in industry. Apart from that, students will also be able to develop skills

essentially in the field of management, communication and work ethics as well as

gaining teamwork experience. Besides, the purpose of InTra is also to establish a

closer relationship between the industries and UniKL.

The learning outcome of this industrial trainings are to ensure by the

completion of this course, students should be capable to exhibit skills in

communication, management and teamwork, adopting ethics, professionalism

1
and HSE practices and to demonstrate incessant building of skills and

knowledge, as well as the gratitude of sustainability issues in industry. The

trainee was attached to the Production and Manufacturing Department under the

supervision of Mr. Syed Zulkhieriee bin Syed Hussin, Production and

Manufacturing Manager of PETRONAS LUBRICANT INTERNATIONAL

SDN.BHD, MELAKA LUBE BLENDING PLANT (MLBP) and Mr. Harmie

Azrak Maat, Supervisor of MLBP. There are several tasks that have been given

to the trainee during the InTra period. The trainee was asked to do Operation

Procedures, Overall Equipment efficiency (OEE) and some other general tasks.

Job scopes of Production and Manufacturing Department includes:

 Responsible in assisting and monitoring the production line in the plant

 Provide the exact Measurement for any product and determine how much raw

materials needed for certain product

 Guarantee conformance to specifications for every raw material before being

processed and conformance for every product as it is completed the blending

process

 Responsible to determine the production rate according to the customer’s

request

 Packaging process is under the responsibility of Production and

Manufacturing Department

 Record and documented all data of daily production and packaging process.

 Transfer finished products to mill and to the vendors

 Make sure all workers in the production line done the job accordingly to

ensure optimum production rate

2
CHAPTER II

GENERAL OVERVIEW OF PETRONAS LUBRICANTS


INTERNATIONAL (PLI)

Recognized as one of PETRONAS’s owned subsidiary, the leading

national oil corporation. PLI was first reinvented in the year of 2008, PLI

manufactures and markets wide range of high quality automotive and industrial

lubricants products in over 80 markets globally. PLI is the collaboration of two

giant lubrication fluids companies, which was a combination of FL Selenia and

PETRONAS’s own Lubricant Unit. Resulting from this, both corporations

focused their structure and contributing the finest lubrication fluid globally. Fluid

Technology Solutions™ is the main PLI’s driving factor to be the role player in

lubricants industry.

Basically, Fluid Technology Solutions™ is more concern in giving the

best lubrication to meet optimum performance level to the right machinery and

engines. To achieve this excellency PLI designed, developed the most suitable

and economical fluid to al range of engines. The origin of PLI's Fluid Technology

Solutions™ information in-flow can be identified through its sources; the User

Market, the Resource Market and the Legislative Requirement. Information is

worthy only if it is put to good use. At PLI, the information in-flow is filtered as

well as further enhanced by the experts of various fields. Prospects are furthered

to all sections notably the heart of PLI's Fluid Technology Solutions™ module, to

be literally dismembered and reassembled. Here, in the hands of able Research

3
and Development scientists, the pursuit to create intelligent fluid begins. User

Market will determine the demand of our lubricants effectiveness. The

requirements are evaluated by the manufacturer of the mechanical called OEM

(Original Equipment Manufacturer), the consumers of the mechanical fragments,

and the when the mechanical part operates under normal situation.

PLI has placed few people in the User Market to obtain real time data thus

using it in designing intelligent fluid that can optimize the mechanical

components as they are designed to. Lubrication fluids were originated by

upstream to form two main raw materials: base oil and additives. Thus, it is very

important to research and study these raw material capabilities in order to align

with resource market.

2.1 History of PETRONAS Lubricant International

YEAR DEVELOPMENT

Presenting FIAT’s lubrication division. Responsible to produce “first


1912
fill” lubrication for all marketable FIAT vehicles.

FL managed to break the barrier out of Italian national market and


1929
successfully spread to Europe.

1974 Petroliam Nasional (PETRONAS) was established.

1976 FL is now recognized as self-governing and attained autonomy status.

Tutela Lubrificantes Company was first produced in Brazil and Olio


1980
Fiat Espanola in Spain. FL initiated its growth around the globe.

1981 Products were fully imported Malaysia. Under privilege of

4
PETRONAS Dagangan, PETRONAS market the lubricant products in

nationally transferring to their service stations.

Blending process by PETRONAS Dagangan and filled in PETRONAS’

1987 Lubricant products locally, including third party technology partners

and in France and United Kingdom FL expansion was founded.

1991 In Germany new branched was established.

PETRONAS’ own lubricant formulations were developed by


1992
PETRONAS DAGANGAN.

1993 FL entered the Turkish and Portuguese markets.

Establishment of Melaka lube blending plant. PETRONAS became a

1994 key player in the industry, with certification to develop own formulas

alongside manufacturing it. FL opens its market in Poland.

First international debut of PETRONAS’ lubricant product in


1995
Cambodia.

1996 Partnership of FL with Holland and Same Deutz Fahr Group.

Establishment of FL Nordic and FL Austria. formerly serving in the

Scandinavian lube markets.


1997
PETRONAS’ lubricant products exported to Thailand, Myanmar and

Vietnams lube trade.

In order to enter international lubricant business PETRONAS Lubricant

1998 Unit was founded. PETRONAS’ lubricant products successfully

entered Hong Kong lube market.

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YEAR DEVELOPMENT

1991 Philippines received lubricants form PETRONAS’ Lubricant Unit

New commercial branch was opened in Argentina. Moment later, FL

decided to detach from Fiat Group and re-branding to be FL Selenia.

There is an independent private equity fund management company that

acquired this, Doughty Hanson & Co, in a transaction of leveraged buy-

2000 out.

Somewhere in December, Viscosity oil, an American company was

bought by FL Selenia. They run most of the important transmission oil

additive. FL Selenia successfully representing itself as a global leading

company lubricants manufacturing for the agricultural industry.

Rondine Azienda Petrolchimica, a lubricants blender and packager was

acquired by FL Selenia. An American private equity firm. Vestar

2003 Capital Partners, later acquired FL Selenia.

In order to allow the entry of lubricants to Indonesia, PT PETRONAS

Niaga Indonesia was established,

Meanwhile in Shenzhen, China the world’s most populous nation. A


2004
PETRONAS Marketing China Company Limited was set up.

For the automotive sector Misal Arexons truly a leading Company in

the production of chemical products however FL Selenia managed to


2005
aquire it. Later an American private equity firm, KKR has acquired FL

Selenia.

PETRONAS Marketing India Private Limited in Mumbai was set up by


2006
PETRONAS’ Lubricant Unit

2008 PETRONAS acquiring the FL Selenia. PETRONAS Lubricants

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International or PLI was established and all PETRONAS lubricants

business is conducted under this company. Aldino Bellazzini, formerly

worked as CEO of FL Selenia renowned as the first CEO of PLI. At its

establishment, with estimated sales volume of 650 million litres a year

PLI was at top 20 lubricant player in the world.

Shandong St Maria Lubricating Oil Company Limited in China was the


2010
first PLI’s acquisition.

Inheriting the legacy from FL’s expert technology in fluids and

lubricants since 1912, PETRONAS Lubricants International (PLI) has


2012
reached 100 years of operation with a slogan “A Century of Fluids

Innovation”.

2.2 Corporate Profile & Core Business

On 17 August 1974 Petroliam Nasional (PETRONAS) was born, a

national oil company of Malaysia, the ownership and the petroleum resources in

the country is entirely taken by PETRONAS. It climbed as regular Malaysia’s

upstream sector and finally reached status as integrated Oil and Gas Corporation,

as FORTUNE Global 500® largest corporations in the world, PETRONAS

succeed. The group has approached in varieties of accomplishments, primarily

upstream exploration and production of oil and gas transferred to the; marketing

and distribution of petroleum products, business, downstream oil refining, gas

synthesis and liquidification, operating gas pipeline transmission, liquefied natural

gas trading, manufacturing and marketing of petrochemical, shipping and assets

investment.

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Currently they more than 60 companies lies under its downstream

business, primarily doing businesses in Refining and Trading, Downstream

Marketing and PETRONAS Chemicals Group Berhad (PCGB) which roles a

strategic character in bringing higher value to petroleum resources. With its status

as the leading trader of Malaysian petroleum yields with a market share of 43.2%

in total. In South Africa, Indonesia, Sudan, Thailand, and 28 others PETRONAS

successfully established the presence as a main trader.

PLI has seven blending and filling plants in total situated in 6

manufacturing countries. Here are the plants established by PLI, Contagem of

Brazil, main plant located in Turin and Naples of Italy, Durban of South Africa,

Barcelona of Spain, Hemiksem of Belgium and Malaysian plant located in

Melaka. These plants specially designed to yield exact quality as ever produced in

the laboratory, automatic control system were fitted out at these plants. The

system can automated batch blending with addition of bulk components from

storage tanks and digitalised control of various critical devices such as mixers,

blenders, premixers, heaters, pumps and valves. Aside from attaining persistent

and precision, it also able to eliminate any unexpected errors.

On the other hand, PLI’s filling technology provides the automatic as well

as manual adjustable lines. This features make PLI to have flexible ability in

filling its fluids into various package size as per requested by the users. Entirely,

PLI plants also have been certified with ISO9001 for quality management and

ISO14001 for environmental management. Preciously there two Research &

Development Centres (R&D) covering the West and the East, one of it situated in

8
Turin, Italy and another one situated here in Bangi, Malaysia. Both facilities are

wholly equipped with the up-to-date instrumentations to perform extensive tests

on development of PETRONAS fluids, example of the test are as following:

liquid and gas chromatography, infrared particle emission, plasma magnetic field,

thermal analysis, tri-biological tests. PLI provides numerous engine test cells to

perform all kinds of fluid development works. This facility helps PLI to counter

the needs of automotive industry.to make these test more real PLI uses bench and

dynamometers with advance automatic drivers. PLI’s R&D centres can be

considered as most well-funded playgrounds to engineers, OEMs and corporate

users in solving the puzzle of the best lube possible.

Head
Head of of Operation
Operation

ZULKIFLI
ZULKIFLI E4 E4

Manager, HSEQ Manager, Manager, Plant Mod. & Manager,


Manufacturing Maintenance Planning & Logistic
AZMAN E3 SYED E3 RAZAK E3 AZRIN E3

Executive, Quality Executive, HSE Chemist Executive, Executive, Executive, Executive, Distrib&
Executive,
Assurance Blending Production Maintenance Executive, Production Logistic
Inventory Planning
ZAKIAH E1/E2 AZAM E1/E2 HUZAIRI E1/E2 SHEIKH E1/E2 HAFIZAL E1/E2 MEOR E1/E2 AZHAM E1/E2 AZRIL E1/E2 FAIZ E1/E2

Assistant Assistant Laboratory Supervisor Inventory Blending Supervisor Filling Supervisor Executive, Assistant
Supervisor Maintenance Planner
MASLIYANA NE IKHWAN NE KHAIRUL NE SHAHAL NE AMRAN NE SUFFIAN NE AZWAN E1/E2 HAFIZAH NE
SOHAIMI NE HARMIE NE HUSSIN NE ASILAH NE
Laboratory Technician Chargeman
Assistant DCS Controller DCS Controller
ZAINUDIN NE NORDIN NE
MUSTAKIM NE LIYANA NE NOORHSAM NE MOHD NE
SHAHRIL NE
Supervisor,
Maintenance
Boilerman ROSLAN NE

MAHADZIR NE Instrument
JAAFAR NE Technician
ROSMAINI NE
MUZAMIR NE
HANIF NE

Mechanical
Technician
HAFIZ NE
HALIL NE

Figure 2. 1 : Organisation Chart of the MLBP (2016)

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2.3 Corporate Logo

Figure 2. 2 : Corporate Logo of PETRONAS

2.4 Vision and Mission

Petronas Lubricants International eager to be a top competitor among the


main players of lubrication fluid in the world market.

Thus, PLI will focus on three core efforts;

i. By the assistant of leading technology and marketing capabilities, PLI


will develop itself as a quick to respond lubrication fluids company.

ii. As the next-generation vehicles is continuously developing now, PLI


aims to become the trusted suppliers of lubrication fluids so that PLI is
now positioning itself as the most preferred corporation of global OEMs.

iii. Quality, reliability and technology are the main factor of PLI to build
relation with worldwide corporation and maintain resilient association.

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2.5 Types of Products

There are various types of products produced at the Melaka Lube Blending

Plant. The products vary according to the type of raw material received, and the

difference in packaging the finished goods. The process of raw materials received

is from Petronas Penapisan Melaka Sdn Bhd, and Vendors via road tankers and

vessels. The base oil is loaded into the tank farms in the plant. It is considered a

simple process of blending. The plant receives more than 100 different kinds of

Base oil and Additives in various packaging modes.

Figure 2. 3 : Raw Materials Receiving Process

Figure 2. 4 : Raw Materials Receiving Process

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Figure 2. 5 : Blending and Filling of Lubricants

The process of producing lubricants is simplified as such:

Base oil + Additive  Lubricant

Every year, the Melaka Lube Blending Plant produces more than 500 different

kinds of lubricants. The product categories consist of:

i. Engine Oil

ii. Industrial

iii. Marine Oil

iv. Gear Oil

The products are packaged into different types of packaging ranging from:

i. Bulk Loading

ii. MPL (1000 Litres)

iii. Drum (209 Litres)

iv. Pail (18 Litres)

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v. APE (3, 4, 5 Litres)

vi. Comaco (0.8, 1, 3, 5 Litres)

vii. Serac (0.5, 1 Litres)

These different sizes of packaging will be loaded with the following brands of

PETRONAS lubricants which consist of:

i. SYNTIUM

Resulted from advance R&D by PLI, it succeeds to produce range of SYNTIUM

LUBE. This achievement enhanced PLI status as Mercedes GP PETRONAS

Formula One Team. This products matches stern industry standards and was

designed to adapt with most complex driving condition and challenging routes.

(Refer Appendix D)

Figure 2. 6: Types of PETRONAS Syntium

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ii. URANIA

Specially designed heavy duty lubricants for heavy duty engines. Engineered

experts gather around the world, Urania is primarily latest technology for diesel

engine type. For example CJ-4, its benchmark product is environmental pleasant

lubricant for on and off-road heavy-duty vehicles. Some devices such as Exhaust

Gas Recirculation (EGR) and Diesel Particulate Filter (DPF) are very compatible

with its Low Ash technology. Its Advanced Additive Technology greatly

improved oil usage, oxidation, corrosive and anti-wear agent, and deposit control

at very high thermal conditions. (Refer Appendix E)

Figure 2. 7: Types of PETRONAS URANIA

iii. MACH 5

PETRONAS Mach 5 is a multi-grade engine oil particularly formulated and

engineered to give advance engine fortification and for severe conditions it make

the engine work with supreme efficiency and best performance. It formula consist

of finest quality base oils and advanced additives system thus providing

14
outstanding high temperature and oxidation that reduces oil film thickening at

engine wall high operated on high thermal stress, ant-wear, anti-tear and increase

deposits disposal.(Refer Appendix F)

Figure 2. 8: PETRONAS Mach 5

iv. SPRINTA

PETRONAS SPRINTA specially designed to fill in four stroke engine blocks that

operate under all condition with optimum performance. This lube is formulated

with finest quality of base mixed with special additive arrangement and gives top

engine power performance, cleaner pistons, anti-wear of the gear and clutch

shifting under severe road surface. PETRONAS SPRINTA engineered to sustain

power and torque, gear can be shifted smoothly, and elongate engine lifespan.

(Refer Appendix G)

Figure 2. 9: PETRONAS SPRINTA

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v. HYDRAULIC

PETRONAS Hydraulic EP chains are best anti-wear hydraulic fluids ever

produced by PETRONAS. This oil serves hydraulic systems in industrial and

mobile service which need anti-wear agent. Quality base oils and additive system

were premium chosen providing extensive fortification against wear and

corrosion, better-quality thermal and oxidation steadiness, and help to resist

against rust and foam formation.

Figure 2. 10:PETRONAS HIDRAULIK

vi. JENTERAM

PLI also produces life turbine oil to the costumers. Mostly the oil is used to

lubricate steam turbine, hydroelectric turbine and also frame type gas turbines that

work on gearing system. This turbine oil widely known as Petronas JENTERAM

HC which advances in assisting turbine lubrication. This oil was refined from

high quality crude oil of PETRONAS.

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Figure 2. 11: PETRONAS JENTERAM

vii. GEAR OIL

PETRONAS Gear oil is lubrication liquid for multipurpose gear shifting

mechanism such as transmissions, transfer cases, and differentials in

transportation and machineries.

2.3 Types of Services

PETRONAS Lubricant Internationals strives for its excellent proactive

relationship with its clients through the entire product life cycle with the sales

services. However sales services are being done by PETRONAS DAGANGAN

BHD (PDB). PDB are a marketing body of PETRONAS and accountable for the

trades of PETRONAS Lubricants International goods in Malaysia. In the space of

30 years, PDB has successfully full-fledged in becoming second leading national

lubricant company in this country.

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YAMAHA Motors has signed a deal with PETRONAS LUBRICANTS.

YAMAHA Lubricants had introduced YAMALUBE, their lube recognition to the

word started in 1970. While was launched in Malaysia on July 2008.

YAMALUBE Lubricants was tested in lab and on the road to acquire and

manipulate the real riding conditions for YAMAHA engine to suit local riding

style and conditions especially in long runway and high speed throttle riding.

YAMAHA developed this lube oil so that it is compatible with YAMAHA’s

engines which run in high speed, accelerate in split second performance and also

to ensure protection and fortification of the engine

Besides that, Perodua and Petronas Dagangan Berhad (PDB) have sealed

their partnership for the next five year with the agreement approximately about

RM225 million. PLI responsible to provide Perodua first-fill lubricants for

Perodua’s vehicles. Through this precious Perodua Genuine Oil agreement, the

contract sealed that Perodua using Petronas SL/SM grade engine oil nationwide

worth RM45 million per annum. The Petronas SL/SM will used in all Perodua’s

service centres.

Last but not least, in June 2016, Toyota and PLI have sealed their

partnership where PLI MLBP provides their lubricants for Toyota’s vehicles.

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CHAPTER III

ASSIGNMENTS, GENERAL TASK AND WORK EXPERIENCE IN


PRODUCTION DEPARTMENT AT MLBP

Presenting as engineering student pass in working life, the intern had to

understand the job constraint and the potentials towards the end of the given task.

Attached under production and manufacturing department requires the knowledge

and skills of managing stuffs and controlling the production line. The operators

use their knowledge and skills to monitor and controlling the production line.

They are accountable for ensuring those employers, workers and the machine to

work accordingly in ensuring smooth production.

Moreover, Production and Manufacturing Department, also has a great

bonding with the Quality Assurance Department and Maintenance Department to

maximize production rate, reduces operational losses, work-related problems,

accidents and damages.

Mr. Harmie Azrak Maat has been appointed as the intern supervisor in

charge during 3 months internship program. He is a Supervisor at Petronas

Lubricant International Melaka Lube Blending Plant. The internship period was

started from 7th June 2016 until 30th August 2016 which approximately 13 weeks

including public holidays. The working time for intern starts from 8.00am until

5.00pm for 5 days per week. The intern had been schedule for various topics and

19
tasks as the assignment to be done. Additionally there were few other

responsibilities besides assignment such as site visit, meetings and attend staff

engagement session. Short internship period have less benefits for intern and less

exposed to the number of real job scope. With long internship period, it will help

the intern to gain lots of knowledge and also understand the learning concepts

during study life. The scheduled workloads from the first week until last week are

stated as below:

• Operation Procedure

• Overall Equipment Efficiency (OEE)

The intern also involve in secondary task such as follows:

• Raw Material Transferring From Vessel

• Sampling

• Dipping

3.1 Operation Procedure

Operation procedure is the documentation of step by step instruction

to help workers consistently perform work activities. The intern has completed

two operation procedures during the three months period which are Raw Material

to Production as well Product Changeover at SERAC,APE and COMACO line.

To do operation procedure documentation, first the intern has to read and

understand very carefully the works instructions also see with her own eyes how

the equipment or machines operates. She will consult with the

Technician/Operator in order to get whole idea of the operations. Operation

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Procedure consists of three main parts which are start-up, normal and shut down

operation. Start-up operation involves procedure how to start the equipment for

example which valves need to open or close etc. Normal operation tells what to do

during normal operation, what parameter need to be monitored. Shut-down

operation shows how to safely stop the equipment. Once the whole process is

understand, the intern will start writing the documentation and take photos to be

put in the document. She will also discuss with supervisor for any improvement or

correction in Operation Procedure documentation.

Figure 3. 1: Operation Procedure

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3.2 Overall Equipment Efficiency (OEE)

After the first task had been completed and reviewed, the intern had assigned to

another task which is Overall Equipment Efficiency (OEE) where it is to evaluate

how effectively a manufacturing operation utilized and it is to identify the time

taken for conversions and the unrecorded downtime, hence suggest ways to

improve machine and process efficiency. In order to complete the task assigned,

the intern has gone through meet-up sessions, discuss, and consult with

Production Manager/SV/Operator to conduct a timeline review, time tagging for

selected process lines.

Figure 3. 2: Daily OEE Data Key In

Base Oil Transferring From Vessel

Purpose of this operation is to transfer base oil from vessel to Tanjung Bruas

storage tank. There are several activities covered in order to complete the transfer

operation. First it involves the moving of hose from Tanjung Bruas area to jetty

towed by lorry. Vessel captain will issue document and Loading Master will

certify all the documents. After document verification and lab test has passed,

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valve line up is performed to make sure material is transferred to the correct tank.

All the activities in base oil transferring from vessel will follow checklist. After

hose arrived at the jetty, hose will be connected from jetty manifold to vessel

manifold. From this operation, the intern is able to understand the fundamental of

raw material transferring operation from vessel, concept of pressure during raw

material transferring and pigging in which it used to clear pipeline before the

transferring process occur. The intern is able to understand current concept of

ISGOTT (International Safety Guide for Oil Tankers and Terminals)

Figure 3. 3: Hose Moving from Tg. Bruas Tank to Vessel

Figure 3. 4: Connecting Hose from Jetty to Vessel Manifold

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Sampling

Sampling is done for the purpose of ensuring the quality of material to be similar as

stated in Certificate of Quality (COQ). The intern has learnt and practice sampling

from drum, and from tank. Usually 1L bottle sample drum is used to take sample

from drum, drum mixer is used to ensure homogeneity of the drum. Sample from

tank can be taken either from the top or bottom of tank. Sample from top of tank can

be taken using sample catcher that traps certain amount of liquid. Sample from

bottom of tank can be taken at drain outlet valve.

Figure 3. 5: Sampling from Drum

Figure 3. 6: Sampling from Top of Tank

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Dipping

Dipping is a process to gain level and temperature reading at the tank. To get the

level reading, either by mode ullage or sounding, dipping tape is lowered into the

tank through the gauge hatch. Mode sounding is normally used for low viscosity

material inside the tank meanwhile ullage involve high viscosity material. In

sounding, gauge bob is release until it touch tank floor but in ullage mode only until

touch surface of material. To get temperature reading, thermoprob is used by

lowering the thermoprob tip until it immerse in the material.

Figure 3. 7: Tank Dipping Process

25
CHAPTER V

CONCLUSION AND RECOMMENDATIONS

Nearing the first half of the Industrial Training program, the trainee

discovered a lot of new knowledge. Gave her the better understanding regarding the

oil and gas industry which literally met the expectations of her course, as a

mechanical engineering student this is a good advantage for her to practice in future.

Furthermore, the trainee also gained valuable insight of working life and what

it takes to be a successful engineer in an oil and gas industry. In any multi-national

company, communication is the most crucial skills and very important. In order to

successfully complete any given task, successful communicating skills is needed

between all parties. Sometimes in a team work there will be different people with

different background that why effective communication among workers is important.

PETRONAS Lubricants has given me many chances in term of technical

knowledge, working experience, and attaining new skills. Most of the given tasks are

related to actual projects carried out by the company. Participating in actual projects

also gives me experiences in relation to the constraints, limitations and problem that

will arise when involved with a project.

26
In order to improve and make this internship more successful, the company should

keep intern in the organizational loop through emails, memos or staff meetings

Besides, they need to compile a list of secondary tasks for times when interns finish

their assignments ahead of schedule. Next, they need to consider interns as real

employees and teach them about the values of the company. Lastly,

provide professional networking opportunities to help students gain additional

insights into this career and also increase future employment contacts

In conclusion, the Industrial Training conducted by UniKL is very important,

it is very successful in order developing student’s future and helpful towards an

undergraduate’s development towards the working life.

27
REFERENCES

PETRONAS Lubricants International (2014). Research and Development: PLI.


Retrieved July 14, 2014 from PLI Website: http://www.pli.com/Research and
Development /

PETRONAS Lubricants International (2014) PLI FACILITIES. PLI. Retrieved July


14, 2014 from PLI Website: http://www.pli.com/pli facilities/

PETRONAS Lubricants International (2014). History: PLI. Retrieved July 14, 2014
from PLI Website: http://www.pli.com/history/

PETRONAS Lubricants International (2014) Overview. PLI. Retrieved July 14, 2014
from PLI Website: http://www.pli.com/overview/

PETRONAS Lubricants International (2014). types of products. PLI. Retrieved July


14, 2014 from
PLI Website: http://www.pli.com/types of products/

PETRONAS Lubricants International (2014) HSE. PLI. Retrieved July 14, 2014
from PLI Website: http://www.pli.com/HSE/

PETRONAS (n.d). Overview. Retrieved July 14, 2014, from Wikipedia


http://wikipedia.petronas.com/index/php?title=Overview

28
APPENDIX A

Example of Operation Procedure Content 1

Example of Operation Procedure Content 2

29
APPENDIX B

Example of OEE DataUsing Microsoft Excel

Data Presentation for SERAC Line

30
APPENDIX C

Base Oil Storage Tanks Additives Storage Tanks

Maintenance Cabin Laboratory

31
APPENDIX D

Types of SYNTIUM Descriptions

SYNTIUM RACER - Engine oil with totally synthetic multi-grade.

10W-60 - Essential for high power sedans usage.

- Extreme operating conditions on track and road.

- Best lubrication fluids for sports driving.

- F1 technology development for supreme power.

SYNTIUM 5000 AV - Petrol and diesel engines fully synthetic oil.

5W-30 - Supreme engine power, fuel saving and preventing from


wears.

- Elongate oil change and reduce oil oxidation.

- Counterparts with OEM’s high performance standards


particularly Volkswagen.

SYNTIUM 5000 LL - Engine oil with totally synthetic multi-grade.

5W-30 - Supreme engine power and anti-wear agent.

- Counterparts with OEM’s high performance standards


particularly BMW.

SYNTIUM 5000 - Engine oil with totally synthetic multi-grade.

0W-30/OW-40 - Supreme engine power, anti-wear agent and economical.

- All range passenger cars, particularly consuming


emission control maneuvers.

- Engine wear protection at extreme driving conditions

SYNTIUM 3000 - Engine oil with totally synthetic


LL5W-30
- Ideal for high-powered sport sedans

- For extreme operating condition on track and road

1
- Supreme performance fortification, extends engine life

- Counterparts with OEM’s high performance standards


particularly BMW

SYNTIUM 3000 - Synthetic based fluid with distinctive formulation

5W-40 - Outstanding power performance of engine

- Full engine fortification for all extreme terrains and


conditions

- Provides longer lifespan of the engine

- All range of passenger cars

SYNTIUM 1000 - Formulated with premium synthetic based fluid and

15W-50 advanced additives system

- Provides engine fortification and longer lifespan of the


engine

- All range of passenger cars in extreme terrains

SYNTIUM 800 - Synthetic blend engine oil for extreme conditions

10W-30 - Minimises engine wear and tear by eliminating thermal


stability
/ 10W-40
- Total engine protection and performance under
/ 15W-50
extreme conditions

- Provides longer lifespan of the engine

- all means of transportation in extreme circumstances

33
Types of SYNTIUM Descriptions

MOTO

SYNTIUM MOTO - Specialized for four stroke motorcycles engine.

RS-4 - Fully synthetic racing oil synergized by extreme


performance ester.

- Designed for ultimate motor racing and superbike


requirement.

- Formulated with DualTech™ for optimum acceleration,


efficiency and power output.

- Supreme fortification against clutch system slippage and


micro-pitting, cleaner pistons and high temperature
dependability.

- Suitable for all motorcycles made in Japanese, European,


and American

SYNTIUM MOTO - Engine oil engineered with total synthetic SAE 10W-50

4SP - Provides engine fortification and longer lifespan of the


engine under extreme condition.

- Optimum shear stability and effective lubrication lining


condition usually under great thermal stress regimes.

SYNTIUM MOTO - Motorcycle oil with the usage half-synthetic SAE 15W-
50
4SX
- Comply with four-stroke engine assisting in modern high-
revving, heavy loads and high thermal conditions.

supreme engine power performance and cleaner pistons

- Noise lessening and fortification under tough riding


conditions.

-Prevent oil breakdown by the presence of thermal stability


at extreme temperature, and act as anti-wear agent by its

34
flexible protective viscosity.

SYNTIUM MOTO - Friction modifier technology unique formula

SCOOTER - Scooter oil with Semi-synthetic SAE 10W-40.

- Engineered for automatic gear transmission system


scooters and motorcycle engines.

- Cleaner pistons, and longer fortification gears shifting


under unstable road conditions.

- Suitable for Asian and European made scooters, ATVs


and mopeds.

SYNTIUM MOTO - Fortified with Extreme Performance Esters

RS-2 - Finest synthetic lube fluids reinforced with most


favorable performance low- ash additives technology ester.

- Lower friction in the engine, lubricate more, greatly


cleaning the engine, and torque with higher magnitude for
tremendous response and acceleration.

- At high temperature and high revs, oil lining gives


protection and capability.

- 2-stroke race engines has been proven to higher speed


racing, durability, motocross, go-carts, on-

road and off-road riding conditions

SYNTIUM MOTO - Featuring Extraordinary Performance Lower Ash


Additive
2SX
- Engineered with, hydrocracked fluids synthetic base oils,
and extraordinary performance low-ash additives.

- Engine fortification and performance at the best.

racing in high-speed and high-revs, durability, motocross,


go-carts, on-road and off-road riding environments
primarily for two-strokes engines

35
APPENDIX E

Types of URANIA Descriptions

URANIA SUPREMO -Less pollution to the environment even the travelling on


smooth or rough road.
CJ-4-SAE
well-ordered viscosity has increase engine efficiency
15W-40
- Superior engine and parts fortification from soot-
produced wear.

-Advance oxidation mechanism and alkalinity


preservation to ensure longer oil lifespan.

- Able to lubricate the engine during higher thermal


condition and during engine start up.

- Low-Ash technology control the emission of smoke by


the engine.

URANIA TURBO - Outstanding diesel engine performance and high


CI-4 performance turbo-charged engines when driving on
rough condition as result of multi-grade formulation.
SAE 15W-40
- Outstanding engine fortification cleaner engine and
soot-handling capability

- Drain capability that was extended

URANIA CF - API CF specified for Outstanding diesel engine


performance and high performance turbo-charged engines
when driving on rough condition as result of mono-grade
formulation.

- Supreme engine fortification provide cleaner engine.

- Advance soot-handling capability

URANIA CD -API CD specified for Outstanding diesel engine


performance and high performance turbo-charged engines
when driving on rough condition as result of mono-grade

36
formulation.

- Most vehicles applicable this lubricants which it can


improve engine performance while driving in town traffic
even during jam or on the move.

URANIA MAXIMO - Outstanding diesel engine performance and high


performance turbo-charged engines when driving on
rough condition as result of multi-grade formulation.

- Outstanding engine fortification cleaner engine and


soot-handling capability

- Economical value as it can save fuel consumption

URANIA OPTIMO - Outstanding diesel engine performance and high


performance turbo-charged engines when driving on
rough condition as result of multi-grade formulation.

- Outstanding engine fortification cleaner engine and


soot-handling capability

- Drain capability that was extended

37
APPENDIX F

Type of MACH 5 Descriptions

PETRONAS MACH Latest API SM specification multi grade engine oil.

5 SM Provides high performance of engine condition and


protecting the engine while maneuvering under rough
conditions. Improvement in shear stress capability.

Less effort to start up cold engine –e friction and wear


has been reduced.

PETRONAS MACH Extra heavy duty engine oil with supreme liberation.

5 SL Outstanding high temperature and oxidation that reduces


oil film thickening at engine wall high operated on high
thermal stress, anti-wear, and anti-tear and increase
deposits disposal.

Possible for all range of passenger cars specially the


latest advance performance vehicles.

Suitable for engine s requiring API SJ, SH, SG or lower


performance level.

38
APPENDIX G

Type of PETRONAS DESCRIPTION

SPRINTA

PETRONAS SPRINTA Four-stroke motorcycle oil superior performance.

4XP Leading technology to fill in four-stroke engine oil and


can be operated under all road surface and weather.

Japanese, European, and American bikes where API SL


and JASO MA2 applied can be filled with this oil.

PETRONAS SPRINTA SAE 20W-40 motorcycle engine oil mostly used in four-
stroke engines running on extreme and all season riding
4XT
conditions.

Lower friction in the engine, lubricate more, greatly


cleaning the engine, and torque with higher magnitude
for tremendous response and acceleration.

Suitable for all riding style and road surfaces.

PETRONAS SPRINTA Superior performance two-stroke motorcycle oil.

2XT Formulate for superior high performance of modern


riding conditions.

Recommended for two-stroke motorcycle engine with


automatic oil injection or premix systems.

39

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