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CHAPTER I
PREFACE
1.1 Overview
This Industrial training is one of the requirements for all RETI’s final semester
students in Diploma Course. The main obe!tive of it is to give student vast e"posure
to a real industrial environment. #ll students of RETI are obliged to perform this
training industr$ !ourse for si" months.
This training is performed to give e"posure and open student%s mind on
operations and real a!tivities at wor&pla!es. Through training industr$' students are
e"posed to how wor& is done at wor&pla!es a!!ording to their respe!tive orders and
regulations.
It also will e"pand and in!rease s&ills needed b$ student espe!iall$ under
guidan!e from a professionals in the industr$. Therefore' training industr$ a!ts as
preparation for students to prepare themselves for real wor&ing e"perien!e.
# guideboo& is given to students to a!t as a referen!e and guidelines to In(
plant training' Organisation !ommittee ) Compan$' *upervisor Compan$' Department
*upervisor and student. It provides guidelines about fun!tion or role of ne!essit$ in
pla$ b$ all parties whi!h involves with training industr$' that !overs what training is
needed and what will be evaluated.
1.+ Definition
Industrial training is a !ourse whi!h is done b$ organi,ation student ) !ompan$ about
the field of maritime' seaport' oil - gas' safet$ and health emplo$ee in term fi"ed to
see& real e"perien!e with pra!tise what we have studied in the institution RETI/
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1.0 ission
Industrial training obe!tive was to engage students with e"perien!e in organi,ation )
!ompan$ whi!h are related to produ!e a graduate that has s&ills and qualit$ for the
near future in real wor& environment.
1.2 Obe!tives
i. To e"pose the students to the real situation of the wa$s of how to operate'
develop and manage at the wor& pla!e a!!ordingl$.
ii. Enable students to appl$ their te!hni!al &nowledge and engineering methods to
real(life situations.iii. To e"perien!e what it is li&e to wor& in a professional organisation.
iv. To in!rease student’s te!hni!al' interpersonal and !ommuni!ation s&ills both
oral and written.
v. To motivate the students to build up their performan!e in the students’
a!ademi!.
1.3 Importan!e’s
i. To in!rease the !apabilit$ of the students in their te!hni!al s&ills.
ii. To ease students to get a ob.
iii. To in!rease the students’ interest in their !ourse.iv. To e"pose the student to the real world of field wor&.
v. To in!rease the students’ s&ills and !reativit$.
1.4 *!ope Training
Organi,ation ) !ompan$ whi!h offer Industrial Training to students must be in
!onun!tion to edu!ate the students in man$ aspe!ts' su!h as maritime engineering
and o!!upational safet$ - health pra!ti!alit$. *!ope of wor& proposed is5
i. 6e!ome development proe!t member in maritime' seaport' oil - gas and
o!!upational safet$ - health' !arr$ing out suitabilit$ resear!h' anal$sis' design'
installation' organi,e and assessment and ris& management.
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In 7a&hoda 8aut’s !orporate !ulture' new ideas are wel!ome. There are lots of
opportunities' su!h as' e!hani!al servi!es' 9a!ilities - aintenan!e servi!es' and
Instrumentation pro!ess !ontrol.
+.+ Compan$’s 6a!&ground
7#:;OD# 8#
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• ;T *wit!hgear and Transformer installation
• ;T - 8B Cable Distribution *$stem
• 8ow Boltage Ele!tri!al or&
• Aenerator *et' 9requen!$ Converter and otor installation
• 8ighting *$stem
• *treet 8ighting - Compound 8ighting *$stem
• ob
• ;eater servi!e and maintenan!e
• Cooler servi!e and maintenan!e
• 9ilter servi!e and maintenan!e
• 6oiler servi!e and maintenan!e
• Condenser servi!e and maintenan!e
• 9lushing servi!e and maintenan!e
• 9lushing pipelines servi!e and maintenan!e
• Balves maintenan!e
+. Compan$ Organisation
@roe!t teams are formed within 7#:;OD# 8#ob Categor$ 6umiputra 7on(6umiputra
anagement ) #dmin + =
Engineer + =
*upervisor 1 1
Emplo$ee Te!hni!al/ + 2
@ra!ti!al *tudent 4 =
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Diagram 2: List of the staffs
CHAPTER III
INDUSTRIAL TRAINING ACTIVITIES SUMMARY
ent to the offi!e 0rd #ugust for internship registration and set the date
for e(pass indu!tion !lass and CID6 !lass. Then' the e(pass indu!tion
!lass was held on the th #ugust and CID6 !lass on the 11th.
• ee& 1 to +5 0rd #ugust F 14th #ugust +=13
or& on board bun&ering vessel' Cendor.
*ervi!e lube oil pump.
Running test the pump to ensure no lea&age and smooth
operation.
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Diagram 3: L.O Cooler Cleaned the 8.O Cooler
ent to ;E to wor& on board 87A @uteri Intan.
Remove 2 units 9eed ater *ervi!e @ump.
6rought the items to wor&shop for !hemi!al !leaning
and pressure test.
• ee& 0 to 25 1th #ugust F 0=th #ugust +=13
Carried out pressure test to all 2 units feed water pump
6rought the items on board 87A @uteri Intan.
Refit all 2 units 9@ in ship’s wor&shop.
Remove + units ounting Balve from air bottle.
6rought the items to boiler wor&shop for overhaul.
Diagram : !ressure esting
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Diagram #: !ressure $auge %ith !ressure
Rigging out lube oil pump in steering gear room on
board !endor. Refit on new platform.
• ee& 3 to 45 1st *eptember F 10th *eptember +=13
Inspe!t main steam !ondenser on board @uteri Intan.
Ta&e measurement and detail to get new steam
!ondenser. 6rought steam !ondenser to wor&shop for disposal..
Refit two units mounting valve to main air bottle. or&shop !leaning.
Inspe!t tools at ;E Inspe!tion or&shop
Rigging sea water servi!e pump on new platform.
Running test to ensure smooth operation.
• ee& to 5 12th *eptember F +th *eptember +=13
Overhaul Re!ipro!ating !ompressor on board @uteri
Delima.
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Diagram & : L.' Cooler Refit fresh water pump in bosun room on board !endor.
or&ed on the turbine !ooler and 8.O !ooler for @uteri
utiara 1 87A 6rought the items to wor&shop for !hemi!al !leaning
and pressure test ade a new gas&et for the items
6rought ba!& the item to vessel to its pla!e
• ee& G to 1=5 +th *eptember F 11th O!tober +=13
Remove au"iliar$ engine air !ooler and main engine air
!ooler from T Ontari.
Diagram (: )ain *ngine +ir Cooler
6rought to wor&shop for !hemi!al !leaning and
pressure test. @ainted both au"iliar$ and main engine air !ooler.
Repla!e new ,in! anode at both !overs.
6rought ba!& the au"iliar$ and main engine air !ooler
to the ship. #ssembled the items
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Running test to indi!ate an$ lea&age.
;ouse&eeping wor&shop.
• ee& 11 to 1+5 1+th O!tober F +3th O!tober +=13
or&ed on the atmospheri! !ondenser and main !ooler
on board alteese .
Diagram ,: +tmospheric Condenser
6rought the items to wor&shop for !hemi!al !leaning
ade a new gas&et and repaint the bod$ and power
brushed the items #pplied high pressure air to ea!h tube inside the !ooler
to remove !ho&e. Read$ for pressure test and inspe!tion
Reassembled the items
7ew proe!t on @uteri Delima 87A
or&ed on the atmospheri! !ondenser' purifier and
turbine !ooler
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The items was sent to wor&shop for !hemi!al !leaning
Repaint the items and made a new gas&et and renew
damaged tubes
• ee& 10 to 125 +4th O!tober F th 7ovember +=13
@ressure tested on the !ondenser and !ooler
6rought the items on board @uteri Delima.
Refit the items
Rigging out main engine air !ooler on board 6russels.
Remove + units au"iliar$ engine air !ooler.
6rought the items to wor&shop for !hemi!al !leaning
and pressure test. Carried out flushing.
ade up new rubber gas&et for the items.
6rought ba!& the items to vessel and rigged to its pla!e.
• ee& 13 to 145 Gth 7ovember F ++nd 7ovember +=13
7ew proe!t on @uteri 7ilam 87A
or&ed on the 8.O and 9. heater
Dismantle the items and rigged under the s&$light
#s usual' the items were sent to the wor&shop
Chemi!al !leaned b$ degreasing the heater for two da$s
and brought to wor&shop for pressure test Che!&ed b$ 0rd engineer during the pressure test
Diagram -: !ressure est %as done
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Refit the !overs
• ee& 1 to 15 +0rd 7ovember F 4th De!ember +=14
6rought ba!& the items to vessel and rigged to its pla!e
:eep the tools and mis!ellaneous items in the lo!&er
Refit new oil water separator on board !endor. Running test to ensure smooth operation.
7ew proe!t on board *ea Bision
or&ed on the 8.O and 9.O heater' CO@T !ondenser
Diagram 1': .O /eater Dismantle the items and rigged under the s&$light
The items were brought to wor&shop
•
ee& 1G to +=5 th
De!ember F +=th
De!ember +=13 Chemi!al !leaning b$ degreasing the bod$ and shell
tubes using vitsol es +3/
9inish off with fresh water and left the items with
!hemi!al for a da$ 9inal !hemi!al !leaning and pressure test was done on
the bod$ and tube side The test was !he!&ed b$ !hief engineer
The items were brought ba!& to vessel and rigged to its
pla!e and refit the itemsb Clean the CO@T Condenser on board with fresh water.
• ee& +1 to ++5 +1st De!ember +=13 F 0rd >anuar$ +=14
7ew proe!t on board 7auti!a 6ergading 9@*O vessel.
Remove all valves at sludge tan& and rigged tan& out of
the frame. Rigged out in!enarator from frame.
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Diagram 11: 0ncenarator
Remove + units lube oil pump in @urifier Room.
Remove atmospheri! !ondenser from tan& to be
brought to boiler wor&shop. Remove diesel servi!e tan&
Remove 8.O Cooler
• ee& +0 to +25 2th >anuar$ F 1th >anuar$ +=14
7ew proe!t on *: *plendor 87A
or&ed on the 8.O ;eaters and 9. 9eedwater
Dismantle the heater and brought the items under
s&$light Ta&e off the feedwater !over and wash it with fresh
water and power brushed the surfa!e
The heaters were !hemi!al !leaned b$ degreaser vitsol
es +3/ and left it for two da$s.
• ee& +3 to +45 1th >anuar$ F 0rd 9ebruar$ +=14
7ew proe!t at IOI Edible Oil.
6oiler inspe!tion' Raw water tan& !leaning and Oil tan&
!leaning.
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Diagram 12 : ater tue oiler Cleaning tube using high pressure water et.
Remove all sludge inside water drum.
@ower brush weld surfa!e at tubing to indi!ate an$
!ra!&. Inspe!t all valves.
@ower brush inside !ombustion !hamber.
Repla!e the feedwater !over and standb$ on vessel
9inal da$ of internship was !leaning up at the lo!&ers
and all the items and tools ent to the offi!e to meet the emplo$er for !ompan$’s
stamp and signature to end m$ internship
CHAPTER IV
HEAT EXCHANGERS
2.1 Introdu!tion
# heat e"!hanger is an equipment built for effi!ient heat transfer from one medium to
another. The media tubing is separated b$ a solid wall to prevent mi"ing or be in
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dire!t !onta!t. The$ are widel$ used in spa!e heating' refrigeration' air
!onditioning' power plants' !hemi!al plants' petro!hemi!al plants' petroleum
refineries' natural gas pro!essing' and sewage treatment. The !lassi! e"ample of a
heat e"!hanger is found in an internal !ombustion engine in whi!h a !ir!ulating fluid
&nown as engine !oolant flows through radiator !oils and air flows past the !oils'
whi!h !ools the !oolant and heats the in!oming air .
2.+ Classifi!ation
There are three primar$ !lassifi!ations of heat e"!hangers a!!ording to their flow
arrangement. In parallel(flow heat e"!hangers' the two fluids enter the e"!hanger at
the same end' and travel in parallel to one another to the other side. In !ounter(
flow heat e"!hangers the fluids enter the e"!hanger from opposite ends. The !ounter
!urrent design is the most effi!ient' in that it !an transfer the most heat from the heat
transfer/ medium per unit mass due to the fa!t that the average temperature
differen!e along an$ unit length is higher. In a !ross(flow heat e"!hanger' the fluids
travel roughl$ perpendi!ular to one another through the e"!hanger.
9or effi!ien!$' heat e"!hangers are designed to ma"imi,e the surfa!e area of
the wall between the two fluids' while minimi,ing resistan!e to fluid flow through the
e"!hanger. The e"!hanger%s performan!e !an also be affe!ted b$ the addition of fins
or !orrugations in one or both dire!tions' whi!h in!rease surfa!e area and ma$
!hannel fluid flow or indu!e turbulen!e.
The driving temperature a!ross the heat transfer surfa!e varies with position'
but an appropriate mean temperature !an be defined. In most simple s$stems this is
the Hlog mean temperature differen!eH 8TD/. *ometimes dire!t &nowledge of the
8TD is not available and the 7T< method is used.
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9igure 15 *hell and tube
heat e"!hanger ' single
pass 1F1 parallel flow/
9igure +5 *hell and tube
heat e"!hanger' +(pass
tube side 1F+ !ross flow/
9igure 05 *hell and tube
heat e"!hanger' +(pass
shell side' +(pass tube side
+(+ !ounter !urrent/
Diagram 13: ypes of /eat *changer lo%
2.0 T$pes of ;eat E"!hangers
i. Shell and tube heat exhan!e"
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9igure 15 # shell and tube heat e"!hanger
*hell and tube heat e"!hangers !onsist of series of tubes. One set of these tubes
!ontains the fluid that must be either heated or !ooled. The se!ond fluid runs over the
tubes that are being heated or !ooled so that it !an either provide the heat or absorb
the heat required. # set of tubes is !alled the tube bundle and !an be made up of
several t$pes of tubes5 plain' longitudinall$ finned' et!. *hell and tube heat
e"!hangers are t$pi!all$ used for high(pressure appli!ations with pressures greater
than 0= bar and temperatures greater than +4= C/. This is be!ause the shell and tube
heat e"!hangers are robust due to their shape.
*everal thermal design features must be !onsidered when designing the tubes in the
shell and tube heat e"!hangers5 There !an be man$ variations on the shell and tube
design. T$pi!all$' the ends of ea!h tube are !onne!ted to plenums sometimes !alled
water bo"es/ through holes in tube sheets. The tubes ma$ be straight or bent in the
shape of a
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in gas&et and bra,ing te!hnolog$ have made the plate(t$pe heat e"!hanger
in!reasingl$ pra!ti!al. In ;B#C appli!ations' large heat e"!hangers of this t$pe are
!alled plate(and(frameJ when used in open loops' these heat e"!hangers are normall$
of the gas&et t$pe to allow periodi! disassembl$' !leaning' and inspe!tion. There are
man$ t$pes of permanentl$ bonded plate heat e"!hangers' su!h as dip(bra,ed'
va!uum(bra,ed' and welded plate varieties' and the$ are often spe!ified for !losed(
loop appli!ations su!h as refrigeration. @late heat e"!hangers also differ in the t$pes
of plates that are used' and in the !onfigurations of those plates. *ome plates ma$ be
stamped with H!hevronH' dimpled' or other patterns' where others ma$ have ma!hined
fins and)or grooves.
igure 2: Conceptual diagram of a plate and frame heat echanger
iii. Pha#e$han!e heat exhan!e"#
In addition to heating up or !ooling down fluids in ust a single phase' heat
e"!hangers !an be used either to heat a liquid to evaporate or boil/ it or used
as !ondensers to !ool a vapor and !ondense it to a liquid. In !hemi!al
plants and refineries' reboilers used to heat in!oming feed for distillation towers are
often heat e"!hangers.
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Distillation set(ups t$pi!all$ use !ondensers to !ondense distillate vapors ba!& into
liquid.
@ower plants that use steam(driven turbines !ommonl$ use heat e"!hangers to
boil water into steam. ;eat e"!hangers or similar units for produ!ing steam fromwater are often !alled boilers or steam generators.
In the nu!lear power plants !alled pressuri,ed water rea!tors' spe!ial large heat
e"!hangers pass heat from the primar$ rea!tor plant/ s$stem to the se!ondar$ steam
plant/ s$stem' produ!ing steam from water in the pro!ess. These are !alled steam
generators. #ll fossil(fueled and nu!lear power plants using steam(driven turbines
have surfa!e !ondensers to !onvert the e"haust steam from the turbines into
!ondensate water/ for re(use.
To !onserve energ$ and !ooling !apa!it$ in !hemi!al and other plants' regenerative
heat e"!hangers !an transfer heat from a stream that must be !ooled to another stream
that must be heated' su!h as distillate !ooling and reboiler feed pre(heating.
This term !an also refer to heat e"!hangers that !ontain a material within their
stru!ture that has a !hange of phase. This is usuall$ a solid to liquid phase due to the
small volume differen!e between these states. This !hange of phase effe!tivel$ a!ts as
a buffer be!ause it o!!urs at a !onstant temperature but still allows for the heate"!hanger to a!!ept additional heat. One e"ample where this has been investigated is
for use in high power air!raft ele!troni!s.
;eat e"!hangers fun!tioning in multiphase flow regimes ma$ be sube!t to
the 8eading instabilit$.
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9igure 45 T$pi!al &ettle reboiler used for
industrial distillation towers
9igure 5 T$pi!al water(!ooled surfa!e
!ondenser
Diagram 1: )ultiphase /eat *changer lo%
2.2
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CHAPTER VI
VALVES
3.1 Introdu!tion
# valve is a devi!e that regulates' dire!ts or !ontrols the flow of fluid gases' liquids'
fluidi,ed solid and slurries / b$ opening' !losing or partiall$ obstru!ting various
passagewa$s. Balves are te!hni!all$ fittings' but are usuall$ dis!ussed as a separate
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!ategor$. In an open valve' fluid flows in a dire!tion from higher pressure to lower
pressure.
The simplest' and ver$ an!ient' valve is simpl$ a freel$ hinged flap whi!h drops to
obstru!t fluid gas or liquid / flow in one dire!tion' but is pushed open b$ flow in the
opposite dire!tion. This is !alled a !he!& valve' as it prevents or !he!&s the flow in
one dire!tion. odern !ontrol valves ma$ regulate pressure or flow downstream and
operate on sophisti!ated automation s$stem.
Balves have man$ uses in!luding !ontrolling water for irrigation' industrial uses for
!ontrolling pro!ess' residential uses su!h as on)off and pressure !ontrol to dish and
!lothes washers and taps in the home.
3.+
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9igure 0 5 Aate valve
The wor&ing of the gate valves is prett$ simple as it does not involve an$
!omple" me!hanism. The spindle wheel' whi!h is atta!hed to the spindle rod'
is rotated to move the K gate K at right angle to the flow of the fluid. The
s!rewed spindle wor&s in a nut and lifts the valve to open or !lose the K gate K
between the !ir!ular openings furnished with seats. The valves and the seatsma$ be either tapered or parallel on their fa!ing sides.
II. Alobe valve
Alobe valve is a t$pe of valve that !ommonl$ used on board ships in pla!es
su!h as bilge su!tion lines. # linear motion valve' whi!h regulates the flow of
the fluid' the valve has a globe bulbous / shaped bod$ that houses the valve
seat and dis!.
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9igure 2 5 Alobe valve
The general arrangement of the valve !onsist of the valve seat and the dis!
arranged at right angle to the a"is of the valve. The perpendi!ular movement
of the dis!' awa$ from the valve seat' !auses a spa!e between the dis! and dis!
ring. hi!h opens the valve.
Alobe valves are used e"tensivel$ in industr$ and ver$ frequentl$ in the
marine field. The$ are ver$ popular due to the following !hara!teristi!s5
The$ have long servi!e life
The$ !an !ontrol the flow of the fluid passing
The$ !an be &ept open an$ degree from full open to full !lose.
Ber$ little valve lift is required to attain full flow unli&e gate valves /
# !hange in dire!tion of the fluid !an be done in angular valve
In a globe valve the fluid to be !ontrolled alwa$s flows from below the valve
seat' so as not to pressuri,e the stuffing bo" and the gland pa!&ing. The globe
valves are used for spe!ifi! appli!ations where stringent shut off requirements
e"ist.
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residual tension on the valve bod$ as that !an lead to failure of the
valve bod$ subsequentl$.
The gas&ets that are used in the flanges must be of the !orre!t si,e.
*ome unior engineers when !utting the gas&ets ma&e a small hole in
the !entre' thus effe!tivel$ throttling the flow.
6efore installation of the valve all the pipelines must be !leaned b$ air
blowing or water washing b$ high pressure water. There are man$ instan!es
that some foreign bod$ has fallen between the valve dis! and the valve seat
and leading to the failure of the valve.
The dire!tion of the flow of fluid is mar&ed on the bod$ of the valve. In the
event that a mar&ing is not present or visible' it is a rule of the thumb that the
fluid will flow from below the valve seat ) dis!. This is espe!iall$ important in
a *D7R valve s!rew down non return valve/' be!ause if the flow is from
above the valve dis!' it would !lose the valve b$ the fluid pressure and flow
and a!t as a !he!& valve. In a s!rew lift valve that would not !reate man$
problems' however the flow pattern would be disturbed and flow resistan!e
will in!rease' also it would !reate an unbalan!ed a"ial load on the spindle.The s!rew down non return valve must be installed hori,ontall$ and the
dire!tion of fluid flow should be alwa$s &ept in mind. In the event that the
valve is installed verti!all$' the sediments from the fluid ma$ deposit behind
the valve dis! and disturb its operation.
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CHAPTER VI
CONCLUSION
4.1 Con!lusion
#fter 4 months of training at 7#:;OD# 8#
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general wor& s!ope here but the pra!ti!al students also have got the opportunities to
implement the wor& s!ope with their own strength and abilities during the internship.
It was an advantage for me to be in the ?#)?C Division where I have boosted up m$
s&ills and abilities. The !on!lusion that I !an ma&e is that ala$sia arine and
;eav$ Engineering is the right pla!e for students to do their internship and learn how
to wor&ing in a team.
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CHAPTER VII
COMMENTS AND SUGGESTION
.1 Comments and *uggestion
I re!ommend that unit of industrial training !an be more !ooperative with
industr$ authorities so that the$ are no students will be late for their internship.
College also should !onstantl$ monitor whatever a!tivit$ whi!h is done b$ students.
Then' I hope that !ollege authorities !an provide more info about this
industrial training so that the student would be more understand about it. College
have to ma&e a rules and regulation must be obe$ed b$ students when undergo
internship so all that matters run smoothl$.
9inall$' I also hope that !ollege authorities !ould sent an$ le!turer to ma&e
observation of the student’s internship. College also should give suitable training site
with field ta&en b$ student when in !ollege so that relevan!e b$ what the students
learnt from !ollege.
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%I%LIOGRAPHY
.1 Referen!es
I. Auidan!e and formats for writing industrial training report first edition/
II. www.brighthubengineering.!om
III. *hipengineer.blogspot.m$
IB. www.marineinsight.!om
B. I*O 3G1= ;$drauli! 9luid @ower. Cleaning of ;$drauli! @ipe *$stems.
BI. I*O 3G11 ;$drauli! 9luid @ower. ethods for Coding 8evels of
Contamination b$ *olid @arti!les.
BII. ator @ro!edure 9@1=2E rev.=1. 1/ @ipe *$stem Cleaning and Testing. +/
Chemi!al Cleaning' ;ot Oil 9lushing and @ressure De!a$ Testing.
BIII. olen :emi #*' DE# D@I Chemi!al Cleaning *$stem.
IL. Coulson' >. and Ri!hardson' > 1GGG/. Chemi!al Engineering( 9luid 9low.
;eat Transfer and ass Transfer( Bolume 1J Reed Edu!ational - @rofessional
@ublishing 8TD
L. Dogan Er$ener +==3/' KThermoe!onomi! optimi,ation of baffle spa!ing for
shell and tube heat e"!hangers’' Energ$ Conservation and anagement'
Bolume 2' Issue 11F1+' @ages 12F12G.
LI. A.9.;ewitt' A.8.*hires' T.R.6ott 1GG2/@ro!ess ;eat Transfer' CRC @ress'
In!'