List of oral questions 2nd grade steam cert

This is my second trial, the questions like straight forward, i hope i can pass...InsyaAllah

1. Start and stop boiler operation
2. What is boiler according to act
3. What is heating surface
4. Briefly tell about 13 essential fitting
5. Briefly tell about your boiler water treatment plant
6. Briefly tell about act you know related to boiler
7.What is different water tube and fire tube boiler
8. Online chemical good or not?
9. If you suspect tube crack, what should u do?
10. What type of boiler chemical use at your plant

Second Chance

1. On 13 Dec Oral exam

2. On 14 Dec Paper B

This is my second chance to get steam cert

I hope can do the best

Fire tube boiler flue pass

Soalan oral exam steam cert 21 Jun 2010

Below list of questions that ask by Inspector:

1. Describe all essential fittings for fire tube boiler

2. Type of furnace - corrugated and plain type (die yg bg jawapan)

3.How many flue pass in the fire tube boiler (actually have three for my case, but i answer 2 only)

4. Water gauge glass test

5. Emergency shut down

6. What act that related to boiler


Only 6 question i get, but no question for water treatment

Hopefully i can go through an pass....

gudluck to all of you

17 July 2010 - Flight to Kunak Sabah

1. Good experience and new challenges

2. i hope can do the best for my wife and Irdina

Bangun Semula!!!!!

Tersentak sejenak dentakan jantung
Mendapat khabar kurang senang
Impianku kecundang

Oh entah di mana salah silapnya
Sedangkan semua dah dicuba
Hati asyik memikir
Dunia dah berakhir

Begitulah perasaannya
Kecewa dalam usaha
Manis dah hilang nikmatnya
Pahit yang jelas ketara

Tapi bila direnungkan
Makin kaya pengalaman
Memberikan kekuatan
Untuk bangun semula

Kadangkala kita pantas berlari
Mengejar apa di hadapan
Tersandung pula halangan

Biar luka hanyalah sementara
Tinggalkan parut kau dah usaha
Jangan jadi alasan
Berhenti separuh jalan

Kempas Mill, Thank you for everything

Kempas Palm Oil Mill, Jasin

My Farewell Dinner

1. Thank you very much to all Kempas Mill management and staff that give me full support for last 2 and half years

2. I wish all the best to them and their family


3. I hope can do better at Giram Mill

4. Very sorry for all my weakness and mistakes

Paper Just Finished

1. Engineering Knowledge Paper B for Steam Engineer second grade just finished just now,

2. Feel very relief but next week is paper C, oral

3. I hope can do better for oral next week

4. Thank you very much to all my family especially my love Odah for help me for preparation of steam engineer exam. I love you all...........

Irdina 3 month

2nd grade steam engineer exam

1. Paper Engineering Knowledge - 15 Jun 2010

2. Oral - 21 Jun 2010

3. Place - DOSH Putrajaya


* Preparation still going on, i hope can perform well for this important exam for my career enhancement

Transfer to KKS Giram on 1st July

1. After 2 and half year at KKS Kempas, i was transfered to KKS Giram in Kunak Sabah

2. It will give me a new experience in palm oil mill industry

3. I really hope can be a better engineer at new place with new people

Domestic Inquiry (DI)

2 main principles

1. That no person is to be condemned without being heard and that justice must not only be heard, it must be seen to be done and that the he/she must be given opportunity to defend himself/herself ans state his/her case fully of the allegations leveled against him/her

2. It also requires that no man shall sit in judgment in his own case or in a case which he has interest and that person who sits in judgment must be independent and unbiased


- My first experience as panel member on 2 April 2010 for driving lorry bantu carelessly case
- Very good experience for me

Boiler Fan Draught Indicator

13 essential fittings for boiler

1. two or more safety valves

2. two water gauges

3. a steam pressure gauge

4. a blow down valve or cock

5. two feed pump or alternatively one feed pump and one injector

6. a main steam stop valve

7. a feed check valve

8. an inspector's test pressure gauge attachment

9. a fusible plug

10. a low water alarm

11. a low water fuel cut out

12. the manufacturer's maker name plate

13. a registration plate

Boiler Gauge Glass Testing

I'm done the test last night with my boilerman, Rajakumaran, thank you for him with good explanation and advice.

Steam, water & drain cock



You can see the water level

Tanpa Ku Sedar

Dapatkan Mesej Bergambar di Sini

2nd grade steam engineer exam sylabus

1.2 PART B - ENGINEERING KNOWLEDGE

This part consist of two (2) papers namely -
(i) Paper l - 3 hours
(ii) Paper II - 2 hours

and candidates will be examined for their knowledge on the following subjects:

(a) Steam and Hot Water Boilers

Different types of boilers (e.g. fire and water tubes boilers, vertical shell type,
multitubular underfired, economic package and waste heat); Constructional
details; Mountings and fittings (e.g. water level gauges, steam pressure
gauge, feed water regulator, safety valves, main stop valve, globe valve, gate
valve, check valve, non-return valve); flue gas path pattern (singular or
multiple, and function of baffle plates); and, Starting cold boilers, operating
under emergency situations, idling procedure and maintenance (tubes, shell,
drums, headers, superheater, economiser, furnace, air heater, pumps, fans
and stacks).

(b) Combustion of Fuels

Theory of combustion (condition, constant temperature, constant volume and
constant pressure); Combustion process (supply air, air-fuel mixture,
combustion temperature, combustion time, combustion gases, and
temperature of combustion gases); Gas analysing technique; and, Draft
(natural, forced, draft differential, and factors affecting draft).

(c) Measuring Gauges and Instruments

The purpose, basic working principles, constructional details and functions of
the main parts of commonly used gauges and instrument (e.g. pressure
gauge, thermometer, pyrometer, barometer, salinometer, and hydrometer).

(d) Boiler Repair, Inspection and Maintenence

Repairs of tubes, shell, furnace, fittings and ancillary machinery including the
statutory and technical (standards and codes) requirements; Internal and
external inspection (procedure and implementation); and, Maintenance (daily,
routine and planned).

(e) Boiler Fuel

Solid fuel (e.g. coal, lignite, wood and wood waste); Liquid fuel (petroleum oil,
black liquor and other chemical derivatives); gaseous fuel (LPG, natural gas
and waste heat); composition and properties of different types of fuel; and,
advantage and disadvantage of different type of fuels.

(f) Boiler Water Treatment

Pure water; Impurities; Contaminated feedwater; external and internal
treatment; Hard scale; Soft scale; Carry over; Priming; Foaming; and, Water
treatment programme.

(g) Steam Properties

Steam (wet, saturated, superheated, degree of superheat and fraction);
Temperature-entropy and temperature-enthalpy diagrams; and, application of
wet and superheated steam.

(h) Pump and Compressor

Basic working principles, selection criteria, advantages and disadvantages of
different types of compressors and pumps.

(i) Steam Turbines

Types and working principles (impulse, reaction, combination of impulse and
reaction); and, Safe operation (start-up and shut-down).

(j) Condensers

Types and working principles, construction and construction materials, and
maintenance.

(k) Governors

Types and working principles, function in turbine, and relay mechanism

(l) Materials

Chemical (e.g. carbon, phosphorus, silicon, manganese, chromium, nickel,
molybdenum, cadmium) and physical properties of construction materials;
Mechanical testing (tensile, bend, hardness, nick break and charpy test);
Stress-strain relationship (proportional limit, yield point, ultimate stress,
permanent set, breaking stress point and elastic limit); Heat treatment (e.g.
annealing, normalising, stress releiving, spheroidising, hardening and
tempering) and effect on microstructure; and, Solution treatment.

(m) Mechanical Working of Steel
Hot work (forging and rolling) and cold work (cold roll and cold working)

(n) Creep and Fatigue
Creep and fatigue behaviour, factors affecting and testing method.

(o) Corrosion and Control
Causes (chemical attack, electro-chemical attack and stress influenced);
Prevention and control (surface protection, metal cladding, electroplating);
surface modification (e.g. cladding and chroming), metal spraying, painting,
and cathodic protection.

(p) Welding
Basic principles and different types (e.g. shielded-arc, gas shielded metal arc,
gas shielded tungsten-arc, plasma-arc, electroslag, stud and gas welding);
Weld joint and preparation (butt, lap, fillet and nozzle); Welding defects (e.g.
cracks, cavities, inclusions, lack of penetration, and fusion, imperfect shape),
methods of detection and repairs; and, Destructive testing (e.g. tensile test,
bend test, hardness test, proof test, fatigue test).

(q) Non-Destructive Testing
Non-destructive testing (radiography, ultrasonic, magnetic particle test, dye
penetrant test and eddy-current); NDT operator qualification programme
(national and international); Welding Procedure Qualification and Welder
Performance Qualification Test.


1.3 Part C -Oral Examination

The candidates will be examined for their knowledge in the safe operation of a
Steam Boiler and other auxilliaries. Detail of these are as follows –

(i) Working principles of various type of steam and hot water boilers,
steam turbines and steam engines, and their fittings and functions.
Note: The candidate is expected to know the operation of all types of
boilers, steam engines and steam turbines.

(iii) Boiler operation (e.g Start-up procedure, shut-down, emergency
situation, conditional monitoring (e.g. water hammer, priming, foaming,
familiarisation with all safety features etc). Installation of new boiler,
various type of testing (water gaguge test, steam test etc.); and Basic
boiler water treatment.

(iv) Boiler House management (e.g. Managing Log Book, Safety and
Health aspects in boiler room)

(iv) Plant safety management (Policy statement, arrangement,
implementation, accident prevention); Contingency Plan / Emergency
Response Plan.

(v) The candidate is expected to know how to sketch the steam boiler,
piping system, fittings etc.

(vi) Related provisions under The Factories and Machinery Act 1967 and
regulations made thereunder.

(vii) Identification of parts (e.g. defected samples, failure tubes etc) and
common boiler deposits.

(viii) Boiler inspections (defects identification, proposal for repair, codes and
procedures).

14 March 2010, My first year annivesary

hari ni genap setahun usia perkahwinan aku dan isteri.Alhamdulillah, semoga berkekalan sehingga ke hujung usia.syukur di atas segala rezeki pemberianNya...happy 1st anniversary to us.

Gunung Ledang, Sagil Johor

Tangkah Estate view
Menara telekomunikasi
1276m

Very hot at the top of the mountain
Bukit botak due to renek tree only available
Posing, take by Aswad
Beautiful view
Batu Ampar, need to hold tight to the rope

How they bring stairs to the top, thankz to them
Cave without goat


Memang semput pun, high staircase before reach at first check point
Very energetic before start the journey

My baby girl IRDINA

18 February 2010, Irdina bte Mohd Firdaus was born to this world, Alhamdulillah........

Transcar cylinder lock

New modification for cylinder lock, to avoid misalignment

Condensate actuator valve

To make sure the ball valve fully close during steam charging

Digester insulation

Digester no4 new insulation cover

Sterilizer non return valve

Important item to maintain 35-40 psi cooking time (weekly checking)

First aid and Fire drill Training

Workers try to use fire extinguisher

Explanation by Rosli and Jaafar

Mr. Ong show how to use kain anduh

SCADA System

Automation in Palm Oil Mill

1. Labor shortage

2. Cost effective using continuous sterilizer, eliminate use cages, railtrack, cranes, tippers, transcar, tractor

3. Operator productivity

4. Improve monitoring on processing

5. Reduction mill downtime

6. Improve steam management

7. Reduce oil & kernel losses

Fluctuations of OER

1. Oil Extraction Rate - main KPI for all millers and planters

2. For Kempas Mill, suddenly drop without any changes in the process operation and maintenance. 1st week of Feb >21%, 2nd till 4th week drop to <20%

3. Factors cause annual fluctuation in OER:

a. My responsibility

• Mill Efficiency (to minimize losses ,1.71% oil to FFB)

b. Planters responsibility

• Harvesting procedure,100% loose fruit recovery
  

c. Sudden change of physiology environment /chemical

• Type of planting material/palm age
• Rain/sunlight (now very hot season)

Salam Maulidur Rasul

Dapatkan Mesej Bergambar di Sini

Sterilizer cooking time

1. Before:

Inlet Exhaust Condensate Total
1st peak 10 3 2 15
2nd peak 10 3 2 15
3rd peak 87 4 4 95
Total 120 minit

2. After

Inlet Exhaust Condensate Total
1st peak 12 2 3 17
2nd peak 12 2 3 17
3rd peak 73 3 5 81
Total 115 minit

3. To check - USB %, <3%
- OLWB at sterilizer condensate, <0.7% to sample

Safety Meeting

Safety meeting was done quarterly to focus on safety issues.This meeting need to have at least 2 representative from employer and 2 representative from employee.The agenda discuss are:

1. Chairman greeting
2. Confirmation of last minute
3. Accident record/ Lost Time Injury
4. Workplace inspection report
5. Objective and programme
6. Department report - First aid, fire fighting, environment
7. Other matters

OHSAS 18001 & HACCP

Both of this certification that i need to maintain for my mill. OHSAS is for occupational safety & health while HACCP for food safety since our last product which is Crude Palm Oil is considered food base product.These cert was very beneficial to mill since we need to have certain standard and procedure in order to process fresh fruit bunch with very good quality without give effect to people and community. I need to finish and reply NCR that raise by TQEM since their last audit in Nov 2009

Mid Year KPI

This midyear KPI was not very good for me. Mill throughput and oil efficiency only get rating 1 and 2 respectively while others parameter like cost/ton and mill downtime get satisfactory only.The worst part is my Leadership quality where i get 2 for 4 qualities.My boss give me chance to do better for year end with another 4 month to come.He ask me to become more proactive and focus to a few problems first and try to make it effectively solve.I will make sure all the KPI target was achieved and at the same time prepare for 2nd grade steam cert exam this year.

Palm Oil Mill Experience

Welcome to all of you.This blog will share my experience working at palm oil mill since 3 Dec 2007. Hopefully all of us especially palm oil millers can give support,comment and sharing knowledge to this interesting world.
Thank you very much