CHAPTER 1

INTRODUCTION

1.1 INDUSTRIAL TRAINING

Industrial Training refers to work experience that is relevant to professional

development earlier to graduation. One of the requirements for the award of Diploma of

Engineering is that students must complete for 16 weeks of Industrial Training.

Industrial Training is normally done at third year however certain university done at

fourth year of study

Students should note that Industrial Training is an essential component in the

development of the practical and professional skills required of an Engineer and support

to prospective employment. The industrial training exposed student to the real life of

working environment. Many employers regard this period as a chance to achieve new

employees for future employment. All students should make considerable effort and

Page | 1
give sufficient thought into obtaining the most relevant and effective Industrial Training.

Although difficult, it is desirable to obtain experience in a range of activities. It should

also be noted that developing an awareness of general workplace behaviour and

interpersonal skills are important objectives of the Industrial Training experience.

1.2 OBJECTIVES OF INDUSTRIAL TRAINING

The objectives of industrial training are as follows:

a) To expose students to engineering experience and knowledge. This is required in

industry, where these are not taught in the lecture rooms.

b) To apply the engineering knowledge taught in the lecture rooms in

Industries situations.

c) To get a feel of the work environment.

d) To gain experience in writing reports in engineering

projects.

e) To expose students to the engineers responsibilities and ethics.

f) With all the experience and knowledge acquired, it is hoped at the

Students will be able to choose appropriate work upon graduation.

Page | 2
1.3 ADVANTAGES OF INDUSTRIAL TRAINING

The advantages of industrial training are as follows:

a) The students will experience learning effective job-strategy technique.

b) The students will learn new skills and gain practical work experience as it is still

new for them.

c) The students can expose, explore and make decisions about future career options.

d) The student will be easy to sell themselves when it comes to interview as they

already have experience in the workplace environment.

e) The academic knowledge will combine with hands-on work experience.

f) The networks are building in the selected field of interest.

Page | 3
1.4 LOCATION OF ASIA SLIPWAY AND ENGINEERING SDN.BHD

The industrial training was done at Asia Slipway and Engineering Sdn.Bhd. The

Asia Slipway and Engineering Sdn.Bhd were located at Kampung Sematang Pinang,

Kuala Kedah. The company was located nearby Kuala Kedah River. The Kuala Kedah

river was essential key, where it was used to transport goods to Langkawi Island and

major industrial fishing industry.

1.5 POSITION DURING INDUSTRIAL TRAINING

At Asia Slipway and Engineering Sdn.Bhd there are two section of ship

repairing, there are fishing boat and government ship .The trainee was placed in

government vessel department as technical team.

The technical team responsible to maintain any ship that being deliver from

customer to our company. The technical tem are divided into five section which is

propeller, engine, propeller shaft and maintenance. Each of this section have their own

expertise in their job.

Page | 4
 The company supervisor for the training is Mr. Mohd Izol Khairi Bin Ismail as

Technical Executive for this company. Mr.Izol responsible is to give advice any

technical problem face during repairing any vessel.

1.6 MAJOR TASK DURING INDUSTRIAL TRAINING.

The trainees have been assignment by supervisor to some project during industrial

training period which is:

a) Insulation exhaust system

b) Install throttle cable.

c) Water jet install and uninstall.

d) Clean bilges tank

e) Paint underwater hull

f) Maintain exhaust system

g) Removing propeller and shaft

h) Installation main engine and generator set

i) Pump fresh water tank

j) Pump diesel tank

Page | 5
 CHAPTER 2

BACKGROUND OF THE COMPANY

2.1 ABOUT THE COMPANY

Asia Slipway and Engineering Sdn. Bhd. (ASE) is one of the Engineering

Company. The company, carrying out activities related to the craft and was established

in 1986 where it is located off about 1.5 km from the Langkawi Ferry Terminal and

registered with the Corporation Private Companies. The company is located in the

village of Kampung Sematang Pinang, Kuala Kedah, Kedah.

The company is actively carrying out activities that related to the government

vessel, where this company responsibility to service the vessel. Example of the services

provided were painting and blasting, engine repairing, repairing electrical equipment,

propeller alignment propeller balancing, piping work and other mechanical works, in the
Page | 6
boat such as by fixing air conditioner, replacing new engine blower and hydraulic pump.

The company also access to the machines, the lathe machines, the grinding machines

and cutting machines.

ASIA SLIPWAY AND ENGINEERING SDN.BHD

Name of Company: ASIA SLIPWAY AND ENGINEERING SDN.BHD

Date of Incorporation: 24th September 1985

Board of Director :Abd Ghafar bin Abd Samat.

: Shakila binti Sahamid.

: Mazelan bin Mansor.

: Rafeat bin Mohd Noh.

Registered office : C-19-39A, Dataran 32, No 2 Jalan 19/1

46300 Petaling Jaya, Selangor Darul Ehsan

Buisness Adress : Kampung Sematang Pinang, 06600 Kuala Kedah,

Kedah Darul Aman

Page | 7
2.2 VISION & MISSION OF COMPANY

Vision

 To be a leading competitive shipping and logistics

company in the industry
 A company whose employees and partners identify
themselves with its goals and values

Mission

• To provide the highest level of service to our customers

• Provide the best possible service to our customers

Page | 8
2.3 CORPORATE LOGO

(a) ASE (Asia Slipway Engineering logo)

(b) Company Of Asia Slipway

Page | 9
2.4 PRINCIPLES OF THE COMPANY

The principles of Asia Slipway and Engineering Sdn. Bhd. is based on its

activities. The principles activities of the company are those of building, repairing,

cleaning, storing and providing slipway for barges, vessel and ships.

2.4.1 GENERAL ACTIVITIES

Asia Slipway and Engineering Sdn. Bhd. (ASE) Yard is located at the river

mouth of Kuala Kedah, 10km from the city of Alor Star. ASE were divided into two

section, where the first section is for government and privet ship and second section for

fishing boats. Example of government ship that ASE services is Malaysia Maritime

Enforcement Agency (MMEA), Royal Malaysia Customs, Royal Marine Police, Marine

Department Malaysia, Marine Fishing Department Malaysia and other marine company.

Bellow show the specification of ASE dock.

Main fabrication area: 30,000 sq ft

Covered storage area: 5,000 sq ft

Slipway and Berthing Jetty: 2 slipways

Total tonnage: 700 tonnes

Unutilized area for expansion: 130,680 sq ft

Page | 10
2.4.2 SHIP REPAIR AND MAINTENANCE

ASE offers a wide range of repair, refit and maintenance services for a wide

variety of craft, from manual servicing to refurbishment for aluminum and steel vessels.

Range of services includes the following:

a) Docking and slipping

b) Refurbishment and refit

c) Annual and special surveys for classification requirements

d) Hull work- hull plating construction, fitting, painting, interior and carpentry.

e) Machinery work- fitting, piping air conditioning, engine overhaul and alignment,

pumps, generating sets, hydraulic and pneumatic works and propeller repair.

f) Electrical and electronic services for motors, alternators, wiring, switchboard and

communication and navigational equipment.

g) Emergency repair work.

Page | 11
Figure 2: Layout of the Company

Page | 12
2.4.3 MAJOR EXPERIENCE

i. Experienced on ship repair works with a pool of experienced personnel on

related fields to carry out work professionally with good quality completed in

timely manner.

ii. Experienced on mechanical works such as engine installation, commissioning

and testing of electrical and machinery items, air conditioning and trouble

shooting of mechanical problems on board crafts.

iii. Experienced on electrical and electronic installation, commissioning and testing

of electrical equipment. Also capable to repair and do trouble shooting of

electrical as well as electronic equipment on board vessels.

Figure 3: Example of ship that ASE responsible to do service

Page | 13
2.4.4 COMPANY ORGANIZATION CHART

Executive Chairman

Technical Advisor

Finance and
Operations
Administer
Manager
Manager

Accounts
Engineering Administer
Executive
Manager executive

Hull and Mechanical Electrical

Safety
Purchasing
Shipwright Supervisor Supervisor Supervisor and
supervisor Security
Superviso

Welders Electrician Storekeeper

Machinist

Fitters

Carpenters

Painters
Figure 4: Company organization

Page | 14
 CHAPTER 3

TASK DURING TRAINING PERIOD

3.1 UNDERSTANDING ABOUT THE COMPANY

Asia Slipway and Engineering is the company that focusing in ship services. The

main customer of this company mostly government vessel, and several fishing boat. This

company is situated at strategic places so it is no dispute why the company’s services

always be wanted by the customers.

Page | 15
3.2 INTRODUCTION TO MECHANICAL SECTION

The trainee had been placed in mechanical sections although the companies have

seven sections. In mechanical section, the work scope cover on engine installation,

exhaust system maintenance, pipe work cooling system for engine, hydraulic system,

pumping system and other more.

The mechanical section responsible to repair and handle the machinery

equipment onboard vessel that been docking on this yard. Mechanical team also

responsible to run test on equipment and parts that been repair. In this section they also

have to responsible to arrange the wooden block on cradle that will place the vessel

during up slip process and know each bulkhead position.

Page | 16
3.3 PROJECT AND RESPONSIBLE GIVEN

During 16 weeks period industrial training, the trainee had had been given task

that need to complete in time frame given. The task which is:

a. Cleaning underwater hull

b. Cleaning the barnacle.

c. Removing exhaust silencer

d. Install water jet system

e. Removing exhaust bellow

f. Paint under water hull

g. Installing propeller, shaft and rudder

h. Up slip and down slip the vessel

i. Arrange wooden block on cradle

j. Propeller torque testing

k. Zinc anode installation

l. Sea trial

Page | 17
3.3.1 ARRANGE THE WOOD BLOCK ON CRADLE

Before up slip the vessel on cradle, the wooden block must be arrange. The

location of bulkhead, underwater appendages of vessel must be identified and sensitive

part like sonar, stern tube, propeller and rudder must be avoided. The wooden block

must be place referring on general arrangement of the vessel.

The wooden block will act like cushion and absorb weight of ship where the keel

of ship will rest on it. It also reduces the damage on ship hull. After satisfy with the

arrangement of wooden block, it must be secure with steel wire to avoid any movement

during up slip or down slip the vessel. Figure shows below.

(a) (b)

Figure 5: (a) The cradle and (b) wooden block secure by steel wire

Page | 18
3.3.2 UPSLIP AND DOWNSLIP THE VESSEL

The Asia Slipway and Engineering Sdn. Bhd. used slipway to up slip and down

slip the vessel. The up slip is where vessel will lift up on the dock, while down slip, the

vessel will be launching into water.

Diver used to ensure the keel of ship sit correctly on wooden block. After diver

confirmed the cradle will up slip the vessel on dock.

Before up slip or down slip the vessel, high tide must be considered along with

draft of vessel. This is to ensure it’s have the clearance between keel and cradle before

up slip. Tug boat also need to assist during launching process. Figure 6 shows below.

(a) (b)

Figure 6 (a): Mooring line attached and (b) vessel being up slip process

Page | 19
3.3.3 PAINT UNDERWATER HULL

Underwater hull need be paint with antifouling paint in order to slow the growth

of organisms that attach to the hull and can affect a vessel's performance and durability.

Marine organism that attached to hull of vessel will affect the performance of vessel,

where it will reduce its ability to achieve top speed, damage on hull overtime, and

transport harmful marine organisms to other areas.

In Asia Slipway and Engineering Sdn. Bhd. they used antifouling pain brand

Jouton and International. Before paint job can be started, marine growth on ship hull

need remove using scraper and high pressure water. The antifouling paint need to be

applied twice on ship hull, in order to get best affect. Figure 7 shows below.

(a) (b)

Figure 7: (a) show barnacle vernicle built on ship hull and (b) ship hull after being clean

and paint

Page | 20
3.3.4 REMOVING AND INSTALL EXHAUST SILENCER.

The exhaust silencer device used to reduce noise created from engine. It work by

mixing sea water, heat exhaust and noise creating by engine. This mixture then reduces

the heat and channel to the exhaust nozzle.

Before removing the exhaust silencer, the insulation for exhaust need to be remove.

The insulation made from fiber glass sheet and stitched with stainless steel wire. This

insulation reduces heat created by engine inside engine room. All stitched need to be cut

by cutter.

During this process make sure person working wear face mask, eye protection,

glove and long sleeve shirt. Since fiber glass very harmful to human if inhale or contact

with skin Table 2 shows step to remove exhaust silencer from Malaysia Maritime

Enforcement Agency.

Page | 21
Table 2.The step to remove exhaust silencer from Malaysia Maritime Enforcement

No. Picture Job Description

1.  Exhaust silencer

2. a) Removing heat insulation.

*use face mask and glove while
handling the heat insulation
b) Remove all screw and bolt.
c) Remove exhaust silencer from
exhaust system.

3.  Connection between main exhaust

and exhaust silencer

4.  Exhaust Silencer after being remove

from engine room

Page | 22
3.3.5 INSTALLING WATER JET PROPULSION SYSTEM PENGGALANG 42

A water jet is a marine system that creates a jet of water for propulsion. The

mechanical arrangement can be divided into six section which is inlet duct, impeller

shaft, impeller, stator, nozzle and bucket. Inlet duct is a space where sea water were suck

into nozzle by rotating impeller.

The water then compress then channel to stator where in increase speed of sea

water before exit at nozzle. The water jet system didn’t have rudder to control movement

of vessel, instead it used nozzle to direct water flow left or right. The bucket function is

to reduce vessel speed or to make emergency stop in critical situation. Below show step

to installing Penggalang 42 water jet propulsion system. Table 3 shows the step to install

Penggalang 42 water jet propulsion system.

Page | 23
Table 3. The step to install Penggalang 42 water jet propulsion system.

No Picture Job Description

1.
 Apply lubrication oil on water jet
bush

2.
 Press water jet bush by using
hydraulic press

3.
 Gently press the bush until it
completely fill bush tube

4.
 Now bush inside the water jet tube

Page | 24
No Picture Job Description

5.

 Water jet impeller

6.
 Installing water jet impeller

7.
 Impeller sleeve

8.
 Installing impeller sleeve

Page | 25
No Picture Job Description

9. -Put the silicon before installing the impeller

casing

10.. -Installing impeller casing

11.. -Impeller cone

12. -Installing impeller cone

Page | 26
No Picture Job Description

13..
 Plastic gasket

14.
 Plastic gasket attached to the Impeller
casing.

15.
 Installing steering nozzle

16.
 Installing water jet bucket

Page | 27
No Picture Job Description

17.
 Finish installing port and starboard
water jet system

18.
 Water jet strainer

19.
 Intake body

20.
 Installing water jet strainer

Page | 28
No Picture Job Description

21.
 Inside intake body

22.
 Finish installing water jet strainer

Page | 29
3.3.6 INSTALLING ZINC ANODE ON P 307

Zinc anode used to avoid corrosion on underwater hull cause by sea water. Zinc

and aluminum are generally used in salt water, where the resistivity is generally lower.

Typical uses are for the hulls of ships and boats, offshore pipelines and production

platforms, in salt-water-cooled marine engines, on small boat propellers and rudders,

and for the internal surface of storage tanks.

It works by supplying low voltage to zinc anode and create positive and negative

pole. This different pole prevent hull from corroded and leave zinc anode reduce or loss.

This anode also called sacrificial anode. Before installing the zinc anode, the surface

must be painted with antifouling paint. Figure 8 shows (a) zinc anode, (b) ship hull and

(c) zinc anode after install

(a) (b) (c)

Figure 8: (a) Zinc anode , (b) Ship hull and (c) Zinc anode after install

Page | 30
3.3.7 MAKING GASKET FOR EXHAUST PENGAWAL 43

A gasket is a mechanical seal which fills the space between two or more mating

surfaces, generally to prevent leakage from or into the joined objects while

under compression.

Gasket can be made from plastic, rubber, paper, silicon or metal. For exhaust

system, asbestos gasket were used since ,asbestos can withstand high temperature ..

Figure 9 shows sheet gasket made from asbestos used for exhaust system (a) old gasket,

(b) cutting new gasket in making, (c) new gasket.

(a) (b) (c)

Figure 9: The gasket made from asbestos used for exhaust system (a) old gasket, (b)
cutting new gasket in making,(c) new gasket

Page | 31
3.3.8 INSTALLING PROPELLER, SHAFT AND RUDDER MV PELITA

A propeller is rotating device that convert motion to thrust. Airfoil shaped blade,

and a fluid is accelerated behind the blade. Ship propeller need to be inspect and check

the condition. Any defect must be repair example cavitation damage. Cavitation damage

most occurs on surface of propeller on trailing edge or leading edge

This phenomena cause by design of propeller of speed rotation. The cavitation

will reduce the performance of ship and eventually damage the propeller .Blazing

method used to repair damage cause by cavitation by heating copper rod into area that

damage. Molten copper then place on hole .After this process the propeller need to be

balancing to reduce vibration. During installation everyone who involved must aware

hazard around them.

Sensitive device like electronic steering gear system need to be remove by

authorize person since to calibrate this device take time. Each component must be

marked the position either port or starboard during removing the component to easier the

next

Page | 32
 Table 4:The Step to Install Propeller, Shaft and Rudder MV Pelita

No Picture Job Description

1.  Inside Steering Gear Room MV

Pelita

2.  Packing used to block sea water

from entering the steering gear
room
 made from nylon rope and
coverwith thick grease.

3.  Put packing on rudder shaft hole

port and starboard
 3x layer of packing.
 Screw the steering quadrant cover
port and starboard

4.
 Install rudder arm after finish
installation of steering quadrant

Page | 33
No Picture Job Description

1. -Stern Tube of Mv Pelita

-Apply grease on stern tube

2. -Apply grease on propeller bush before

installing inside stern tube.

3. -Propeller bush being punch

 Avoid apply to much
pressure while hammering.

4. -Finish installation of propeller bush

Page | 34
No Picture Job Description

1. -Port and Stbd propeller of MV Pelita

2. -Propeller being lifting by crane

3. -Technician installing the propeller and

shaft
 apply grease on propeller
shaft

4. -Used chain block to move propeller shaft

into stern tube.
-Finish installing propeller shaft

Page | 35
No Picture Job Description

1. -Port and starboard rudder MV Pelita

2. -Rudder being lifting by chain block into its

position.

3. -Tight the screw and blot of rudder

-Put shaft bracket
 Put cement on screw and bolt
in order to protect from
vernicles growth.
 This to ensure easy removing
screw and bolt while upslip

Page | 36
3.3.9 REMOVING EXHAUST BELLOW FROM PA-4

Exhaust bellow are elastic device that can be compressed when pressure is

applied, or extended under vacuum. It used to compensation and vibration for ship

engine exhaust system. The bellow located near the engine ad silencer is so short. The

bellow absorb movement and vibration produce by engine.

There are two type of bellow made from plastic and metal bellow. For metal

bellow, it can be divided into three type formed, welded and electroformed. Formed

bellows are produced by reworking tubes, normally produced by deep drawing, with a

variety of processes, including cold forming and hydroforming.

Welded bellow is manufactured by welding a number of individually formed

diaphragms to each other. Welded metal bellows are produced with a lower initial

tooling cost and maintain higher performance characteristics. The drawback of welded

bellows is the reduced metal strength at weld joints, caused by the high temperature of

welding

Page | 37
 Electroformed bellows are produced by plating a metal layer onto a model and

subsequently removing the mandrel. They can be produced with modest tooling costs

and with thin walls providing such bellows with high sensitivity and precision

applications.

For bellow used on PA-4, it used metal bellow due to low cost and easy to

maintain. Legging need to be remove before dismantle the exhaust bellow. During this

process person need to ware face mask, eye protection cotton glove and long sleeve

since this material is hazardous. Bellow show the exhaust bellow used and removing

process (a) legging used to insulate exhaust system. (b) Removing exhaust bellow

process and (c) condition after exhaust bellow was been remove.

(a) (b) (c)

Figure 11: (a) Legging used to insulate exhaust system. (b) Removing exhaust bellow
process and (c) Condition after exhaust bellow was been remove.

Page | 38
3.3.10 SEA TRIAL MV SUHAIL

A sea trial is the testing phase where the ship was tested its performance either

after finish the construction or repairing project before delivered to owner. In this

test,MV Suhail set sail to Langkawi Island and the ship was tested on manoeuvrability,

equipment after being repaired and speed. The ship must be 100% tested and condition

of the ship must be in top-notch before returning to owner

During this test there are technical team, owner’s representative, and ship crew

on board ship. The condition during sea trial must be good so the ship can achieve its

maximum speed. Figure 12 shows below.

(a) (b) (c)

Figure 12: (a) and (b)technical team inspect on MV Suhail waterjet system and
(c)during sea trial

Page | 39
 CHAPTER 4

CONCLUSION AND RECOMMENDATION

4.1 CONCLUSION

During INTRA period for 14 weeks at of Asia Slipway and Engineering Sdn.Bhd

(ASE), the trainee has learned more experience and expose to the company organization.

From that experience the trainee can share together.

A successful company, they have received many project from government sector

.The team work can be done by the good interaction between the employer and

employee through their jobs. Besides that, the good communications with others are

important to maintain the good work and high quality. Therefore during the INTRA the

trainee developed and improved his communication skills. With the skill, it can help to

improve the trainee skill and confident to liase with employee, employer and customer.

The trainee has to be responsible during working on their task. With this spirit

the trainee can give full commitment. By having a responsible attitude any trainee can
Page | 40
do any job or task given by the employer without any difficulties and problems and also

by having a responsible attitude, the trainee, they can even someday be an employer by

having their own company.

Punctuality is important in any field, it shown the workers attitude and discipline. For

example the worker has to be punctual when delivered the order to the customer and

fulfil customer satisfaction. It can train the trainee to become discipline and a punctual

person.

During four months in industry training the trainee gained a working experience

in a real working environment. Besides that, the trainee able to improve their confident

level in adapting the real working environment. Trainee also got more skills in handling

their work.

Page | 41
4.2 RECOMMENDATION

Trainee recommended that company to create more structured training program.

Trainee understands that the person responsible to supervise the practical student is

already busy with their work burden. However trainee believe that they can spend more

portion of their time to plan more comprehensive, structured and organized training for

the practical student.

The supervisor in charge should list and arrange the training task which will be

performed by the trainee. In arranging and assigning the training task, the supervisor

also should try to fill the training period with task that significant in developing the

trainee knowledge, skills and experience for its future career.

Lastly, by attending the industrial attachment, trainee know that we must 100%

ready whether mentally or physically because the job in a shipyard demands so much

our energy and effective. Last but not least, trainee won’t regret his decision attending

the industrial attachment in Asia Slipway and Engineering Sdn. Bhd (ASE)

Page | 42
REFERENCE

 Vetus.(1995). Marine Equipment. (3th ed.) Perak.

WEBSITE

 http://www.asiaslipway.com.my

 http://www.wikipedia.org/Anti-fouling -paint.com

 Htttp://www.wikipedia.org/wiki/pump-jet.com

 http://www.marine powerjetpower.com

 http://www.yacthpaint.com

INTERVIEW

 En. Mohd Yusuf Ghazali, General Manager

 En. IszharAzmi, Administration Manager

 Syed Muhammad Taufik Syed Abu Samah, Head of Technical Executive

 Ms Nur Hidayu Salleh, Technical Executive

 Mohd Izol Khairi bin Ismail, Technical Executive

 Muhamad Fikri, Project Team

Page | 43
 APPENDIX

BOAT OR SHIP THAT MAINTENANCE AT ASIA SLIPWAY COMPANY

Figure A1: MV PELITA

Page | 44
Figure A2: KM SIANGIN

Figure A4: MV SUHAIL

FIGURE A5: PENGAWAL 43

Page | 45
Figure A6: KPS SIMILANG 7

Figure A7: P 306

Page | 46