End of Internship in Nestlé - 20th-24th Feb 2017 (8am - 5pm)

Monday, 20th Feb 2017 (8am - 6pm)

At 9.15 a.m., we had a daily review meeting with the operators. 

Between 11.00 a.m. and 12.15 p.m., Tee had called me to meet at the new DAF site and asked me about the procedure for operating the air saturation system. The condition of the water surface in the separator unit was unsatisfactory as certain parts were bubbling and other parts had insufficient air bubbles. We were adjusting the hand valves at air nozzles manually and observing the water surface so that all parts of the DAF unit are injected with numerous fine air bubbles. It took up time for Tee to troubleshoot this problem. 

At 12.30 p.m., Jaclyn asked me to help her monitor the MBR operation and ensure the recording is done by the operator.

Between 8.00 a.m. and 5.00 p.m., I continued to prepare the presentation slide. The slide contents include the projects I was involved such as the new DAF system and filter press. Then I emailed this file to Tee for checking. Meanwhile, I had sent one of my completed tasks, the WWTP flow diagram to Tee for checking as well. 

Tuesday, 21st Feb 2017 (8am - 5pm)

ON LEAVE 

Wednesday, 22nd Feb 2017 (8am - 5pm)

At 9.15 a.m., we had a daily review meeting with the operators as usual.

Between 8.00 a.m. to 2.30 p.m., I updated the SOP of filter press operation and emailed the completed files to Tee. 

Between 2.30 and 5.00 p.m., I continued to prepare and update my presentation slides. Tee had checked my final version of slides. 

Thursday, 23rd Feb 2017 (8am - 5pm)

At 9.15 a.m., we had a daily review meeting with the operators. 

At 10.00 a.m., we were in the meeting room to set up the venue for the presentation. The presentation session began at 10.30 a.m. when Mr Shinya, Head of the Engineering Department, was here. I was the first presenter, followed by Samuel and Yi Jie. Each of us had presented the projects involved and the tasks assigned during this three-month internship. There were Q&A sessions after our presentations. Then Mr Shinya gave a short speech and advice at the end of the presentation session. 

Between 1.30 and 5.00 p.m., I was tidying up all the belongings and obtaining the signature from the superior for approving some document in the Engineering office.

Process flow diagram of wastewater treatment plant

Friday, 24th Feb 2017 (8am - 5pm)

ON LEAVE

END OF INTERNSHIP

THANK YOU

Internship in Nestlé - 17th Feb 2017 (8am - 5pm)

Friday, 17th Feb 2017 (8am - 5pm)

Between 8.00 and 10.30 a.m., as requested by Fam, I did a stock check for spare pumps and motors at the DPRS store room to collect all data. Then, Fam and I carried out the stock check for spare instruments, which are used in DPRS, in the Instrument Room. Those spare instruments, such as transmitters and switches, were in disorder, and we had taken up time to gather all instruments in one box. Later, I updated and completed the Spare Parts List of DPRS before emailing all three Spare Parts Lists to Fam and Tee for checking.

At 9.15 a.m., we had a daily review meeting with the operators. 

At 10.00 a.m., I guided Vasu for strainer cleaning in the DPRS site. This task should be carried out when the internal pressure of the MBR feed pipeline is above 1.0 bar. At the same time, Leon had been here to monitor the MBR operation. He told me that he had detected several programming errors in the PLC system and Maurice would fix this problem at the end of February.

At 11.00 a.m., I went to the DAF site and asked Vasu about the air saturation system, as this system is crucial for an effective dissolved air flotation process. He had explained to me about the parameters to be monitored and adjusted. However, most of the settings were done by the process engineer during the commissioning stage. Later, I updated the SOP of the new DAF system by adding the section on the Air Saturation System in the Engineering office.

Between 3.00 and 5.00 p.m., I attended the second training session on Filter Press operation with Tee and Vasu. This session was mainly about the introduction of the HMI panel, maintenance of the filter press system, detailed operation and specifications. Each of us was given a copy of the operation manual, which includes all detailed information.

Internship in Nestlé - 15-16th Feb 2017 (8am - 5pm)

Wednesday, 15^th Feb 2017 (8am - 5pm)

At 9.15 a.m., we had a daily review meeting with the operators.

Between 9.30 and 10.15 a.m., I was in the WWTP to observe unit operations and conduct a final pipeline tracing. In general, worn pipelines in the entire WWTP were replaced and arranged as an above-ground type.

Between 10.30 a.m. and 12.30 p.m., I was in the WWTP laboratory to conduct an experiment of flocculation in sludge solution by a flocculant, polymer (polyacrylamide) solution. Finally, this experiment could be carried out with the installation of a new sludge feed pump so that the sample can be collected. The sludge sample and polymer solution were taken from the sludge silo with Vasu’s assistance. The objective of this experiment is to determine an optimum polymer dosing for flocculating particles in the sludge mixture before feeding it into the Filter Press system for dewatering. I had recorded the results based on my observations and taken several photos as a reference.

Between 3.00 and 5.00 p.m., I had prepared a laboratory report for the experiment conducted. The format of the report is same as the previous one, which includes procedure, result tabulation, detailed discussions and conclusion.

Sludge Flocculation

Thursday, 16^th Feb 2017 (8am - 5pm)  

At 8.00 a.m., Jaclyn had left a message for me to help her guide the operators about the procedures of MBR desludging and strainer cleaning. Later, I did a final check on the laboratory report, which was prepared yesterday before sending it to Tee.

At 9.15 a.m., we had a daily review meeting with the operators.

At 10.30 a.m., I guided Vasu through the procedure of MBR desludging when MLSS exceeds 10000 mg/L in the DPRS site. The whole process is done manually. However, at 3.00 p.m., I was informed by Leon that he had set a schedule using PLC to carry out a daily desludging step automatically.

From 11.00 a.m. to 12.15 p.m., Fam, Tee, and I had a short meeting to discuss the Spare Parts Lists and the FLOCs. Fam had asked me to help him record the specifications of additional spare pumps which are located in the DPRS storeroom. I had updated those files based on their comments after the meeting. Afterwards, I had shown the material balances of WWTP and parameters to Tee for any feedback.

Meanwhile, I had shown the WWTP flow diagram that I had reviewed and updated during these months. Later, Fam had printed an old version of WWTP mapping in A2 size, which was drawn by a draftsman, to me. I had to mark down any new pipelines and equipment that existed in the current WWTP on this A2 paper for their future reference.

At 2.00 p.m., I had asked Lakman, from the Technical Store, about the systematic approach of recording the spare parts. He explained the method while showing me the guidelines.

At 5.00 p.m., I had sent all three updated FLOCs for the new DAF, DPRS, and Filter Press to Tee and Fam for checking. Tee had given several comments and asked me to update both the SOP of the new DAF system and the Filter Press, especially including a section about the Air Saturation System for the new DAF system.

Internship in Nestlé - 13-14th Feb 2017 (8am - 5pm)

Monday, 13th Feb 2017 (8am - 5pm)

At 9.15 a.m., we had a daily review meeting with the operators.

At 9.45 a.m., I guided the WWTP operator, Vasu to recognize the new DPRS data log sheet in the control room. I told him to use this log sheet onwards for recording DPRS parameters.

Between 9.00 a.m. and 12.00 p.m., Jaclyn had asked me to prepare a guideline for basket strainer cleaning at the DPRS site. She explained the steps of cleaning to me. Later, I went to the site to take several photos to be inserted into the guideline for illustrations. I had emailed the guidelines to Tee and Jaclyn for checking once completed. Then, Tee reminded us to include LOTO practice during cleaning. It is important to apply LOTO for safety purposes.

Between 8.00 a.m. and 5.00 p.m., I continued to prepare the detailed SOP of the new DAF system. After that, I began to prepare another format (simple version) of SOP in flow chart. 

Tuesday, 14th Feb 2017 (8am - 5pm)

At 8.00 a.m., I did a final check on the SOP of the new DAF system before emailing this file to Tee. 

At 9.15 a.m., we had a daily review meeting with the operators as usual. 

At 10.00 a.m., I received an email about the information of the End Internship Presentation, which is scheduled for next Thursday morning. We should prepare a presentation slide about the projects involved.

Between 9.00 a.m. and 5.00 p.m., I was revising and updating the WWTP flow diagram, which was drawn during the early internship period. Meanwhile, Fam had followed up on the Spare Parts Lists, and Tee had informed me that we would have a short meeting to discuss the Spare Parts Lists and FLOCs.  

Internship in Nestlé - 8-10th Feb 2017 (8am - 5pm)

Wednesday, 8th Feb 2017 (8am - 5pm)

At 9.15 a.m., we had a daily review meeting with the operators. Later, I observed the unit operations in WWTP as usual.  Recently, foaming floats have accumulated at the surface of aeration tanks, indicating that activated sludge microorganisms are under a nutrient-limited condition. The nutrient is pumped into the treatment system to improve water quality.

 

Foaming of the aeration tank.

Between 10.00 a.m. and 5.00 p.m., Tee had assigned me to type in the COD of several influent sources for the past four weeks and tabulate a graph using an Excel file. Later, Jaclyn had emailed me a file of the current format of the MBR data log sheet and asked me to key in the handwritten record of DPRS parameters, since the first day, into this file.  

Later, Jaclyn had given me the information about the settings of chemical dosing and level setpoints of the DAF balance tank. She asked me to prepare a simple notice as a guideline for WWTP operators to operate and monitor the new DAF system. I had finished the given tasks and emailed the files to them as soon as possible. Meanwhile, I continued the SOP of the new DAF system.  

At 1.30 p.m., I met Jaclyn at the DPRS site. At the same time, suddenly one of the MBR feed pumps vibrated vigorously. We quickly shut down the MBR operation and noticed that the actual pressure and TMP of MBR MT5700 were extremely high. We had reported this issue to Fam and Maurice online in the control room.

Thursday, 9^th Feb 2017 (8am - 5pm)    

PUBLIC HOLIDAY

Friday, 10^th Feb 2017 (8am - 6pm)

At 9.15 a.m., we had a daily review meeting with the operators as usual.

Between 10.00 a.m. and 5.00 p.m., Jaclyn had asked me to prepare a guideline about the manual desludging from MBR in the case of MLSS higher than 10000 mg/L. Before that, I had gathered the information from Leon about the condition and procedure of MBR desludging. However, I were informed this guideline was prepared for the WWTP operator, and therefore she asked me to prepare this guideline in simple English with attached photos. Meanwhile, I continued the SOP of the new DAF system.

Afterwards, Jaclyn had asked me to help her prepare a new format of MBR data log sheet, including the MC section, so that the operators can easily follow up the recording task. Besides that, the step-by-step guideline for recording should be prepared for them as well. After several discussions and editing, the MBR data log sheet with the latest format and its guidelines was finalised and printed out.

Between 5.00 and 6.00 p.m., Jaclyn and I guided Desa through the steps of recording MBR parameters using the data log sheet of the new format. I stick the guideline inside the DPRS control room.  

Internship in Nestlé - 6-7th Feb 2017 (8am - 5pm)

Monday, 6^th Feb 2017 (8am - 5pm)

At 8.30 a.m., I emailed the punch list of WWTP, which was created last week, to Tee after including all the issues.

At 9.15 a.m., we had a daily review meeting with the operators.

Between 9.30 a.m. and 5.00 p.m., I continued to prepare the SOP of the new DAF system. I had taken several photos of the PLC panel and the instruments of the new DAF system, which would be included in this SOP.

At 11.00 a.m., Jaclyn and I were in the DPRS control room and we noticed that the scheduled 10 a.m. maintenance cleaning (MC) of MBR was aborted. This situation occurred since last week, however the PLC panel just displayed ‘ABORTED’ without any detail. We had informed the project engineer, Fam about this issue.

At 3.00 p.m., Fam, Jaclyn, Christ and I were in the DPRS control room. We had communicated with Maurice online about this issue and required technical support to fix this problem. We exchanged the MC schedule of both MBRs to investigate this issue further.

Tuesday, 7^th Feb 2017 (8am - 5pm)

Between 8.30 a.m. and 12.00 p.m., I updated the Spare Part List for new DAF and DPRS as requested by Jaclyn and with Fam’s guidance. The information on spare parts such as brand and dimension was recorded for future reference. I emailed these files to Fam once completed and checked.

At 9.15 a.m., we had a meeting with the operators as usual.

At 9.50 a.m., Fam asked me to help him monitor the operational mode and parameters (mainly TMP) of MBR during the MC at 10 o’clock later. I went to the DPRS control room to monitor the MBR MT5750 which conducted MC for an hour while the other (MT5700) was in production mode. Eventually, the MC was completed before automatically returning to production mode.

Later at 2.00 p.m., again I monitored the MBR MT5700 which the MC was scheduled at this time. I noticed that once this MBR entered MC mode, the PLC panel immediately displayed ‘ABORTED’, without further stages. I returned to the office to inform Fam about this same issue. I typed the collected data of these two MC periods into an Excel file before emailing this file to Fam.

At 3.15 p.m., we communicated with Maurice about this issue online. 

Internship in Nestlé - 1st-3rd Feb 2017 (8am - 5pm)

Wednesday, 1^st Feb 2017 (8am - 5pm)

At 9.15 a.m., we had a daily review meeting with the operators.

At 11.00 a.m., someone asked me to help him sort the information in his Excel file.

Between 10.00 a.m. and 4.00 p.m., I studied the process flow diagram and P&ID of DAF in the office before performing the pipeline tracing of the new DAF unit which is under operation now. Meanwhile, I took several photos of the tag number of the pump and instruments for FLOC registration of the new DAF unit. Currently, the old DAF unit is shut down and the operators were draining off the remaining content before cleaning the old DAF unit.

Thursday, 2^nd Feb 2017 (8am - 5pm)   

At 9.15 a.m., we had a meeting with the operators. The WWTP operator, Ridzuan had brought out some issues about the operation of the new DAF unit, such as leakage at several parts. Shanji had asked me to follow up on these issues.

At 9.30 a.m., I followed Ridzuan to observe the sections where he mentioned during the meeting. He said there was leakage at the flange of the automatic valve located between the DAF feed pump and flocculator due to a sudden surge during the start-up of the system. Besides that, there is leakage from the sludge discharge compartment. I have taken photos of the sections for reference.

Later Shanji shared with me the template of the Punch List for WWTP. He explained that this list is used to record the issues reflected by the operators in their working areas. Shanji and I generated the list based on the issues reported by the operator.

Friday, 3^rd Feb 2017 (8am - 5pm)

At 9.15 a.m., we had a daily review meeting with the operators.

Between 10.00 a.m. and 4.30 p.m., I completed the FLOC registration of the new DAF system, including the details of the maintenance required. Jaclyn and I monitored the operation of DPRS, especially the parameter (TMP) before and after the scheduled maintenance cleaning of membrane modules in both tanks. Meanwhile, I have begun the SOP of the new DAF unit based on the information recorded last week and the operation manual of the new DAF.