>WEEK 12< DAY 59 - 24 June 2010 (Thursday)

Last day as a trainer at TNB REMACO, Lemal....Many experiences I got when I practical here...All staffs very friendly...I like work with them...

For a last day, i make a small feast to all staff as a appreciation...I met with all staffs and say thank you because teach me...

I also me En Zulkifly to take his sign for my logbook and take a letter as a sign of practical completion...

THAN YOU TNB REMACO LEMAL

>WEEK 12< DAY 58 - 23 June 2010 (Wednesday)

Meeting with all staffs...En Zulkifly as a mechanical engineer explain about two complaints at Pulau Tioman and Pulau Perhentian...The officer from two office want to repair the engine as soon as possible...After make decision, two team must be sent..

All the tools must be prepared because the officer can call anytime to go to its place...Maybe team go to to Pulau Perhentian can go tomorrow and team to Pulau Tioman will go next week...

>WEEK 12< DAY 57 - 22 June 2010 (Tuesday)

Continue clean the cylinder head...Only half have done...

Other work...Make two box with wood to store the fuel pump to sent to Johor.
I help the staffs to make it...

At the evening, clean back the cylinder head...really really tired...

>WEEK 12< DAY 56 - 21 June 2010 (Monday)

Continue clean the cylinder head...
One by one we clean it...
This work take time because we must clean all 18 unit of cylinder head...

Work divided to 2 group..1 group clean the cylinder head and one group clean its component like valve and fuel pump...

>WEEK 12< DAY 55 - 20 June 2010 (Sunday)

Brought down all components taken from kapar...
There are 18 cylinder heads, 18 fuel injector and 18 fuel pump...


After that clean the cylinder head with diesel...

>WEEK 11< DAY 54 - 17 June 2010 (Thursday)

Last day in this week...
Help En Asri to write a report about black start at Kapar...

Discuss about the spare part to be repaired..
We must clean all the component and pack it before sent to workshop at Johor...

>WEEK 11< DAY 53 - 16 June 2010 (Wednesday)

SERVICES ALTERNATOR CHARGER....
Copper brasses always wear when time to come...sometimes it can't charge the battery.. So, we need to check whether the copper brass still can use or not... According to the staff, they said the copper brass is the first thing we check when the alternator charger is malfunction..

>WEEK 11< DAY 52 - 15 June 2010 (Tuesday)

Waiting for Mrs Zeti Akma.. She is the lecturer that will come to visit me...At 10 pm she arrive...Then we all discuss about my practical at TNB Remaco...

The generator set from KB can't work properly...
We must do inspection again...
Skills and experience required for job like this...
At morning, not found what the problem...

After do some research, find the problem...
Relay maybe cause the engine not run well...

Then, the relay changed with new one...
The engine work well....

>WEEK 11< DAY 51 - 14 June 2010 (Monday)

Continue repair generator set 500 kW from Kota Bharu...Last month, we take off the water pump because its broken..After order the spare part we must put it back to the engine...The Dorman engine used for this genset is bigger than other engine...Before we put the water pump in the engine, we must connect the bearing, rod and others in water pump.. The components must be wash with diesel before we pairs..A new gasket must be made...The gasket used to prevent leakage at the connection point.. After washed, we connect all the components for water pump...This work must be done carefully..If neglected, it will cause damage to the component...

>WEEK 11< DAY 50 - 13 June 2010 (Sunday)

Weekly meeting...
Discussed about audit that will come next week...
All staffs was divided into several groups to carry out duties..

I follow a team to clean up the store...
-store old engine
-brush spider nest
-paint

>WEEK 10< DAY 49 - 10 June 2010 (Thursday)

Continue yesterday work


-Jacking the cylinder liner...
-Packing all things and tools...
-Get ready to go back to Lemal

>WEEK 10< DAY 48 - 9 June 2010 (Wednesday)

Continue work
-Cleaning fuel filter, oil filter and centrifugal oil filter
-Cleaning lube oil cooler tube nest
-Measuring inner diameter of cylinder liner
-Cleaning piston and connecting rod
-Measuring piston gap and clearance
-Gauzy the covering piston, connecting rod and bearing with oil and prepare for storage

>WEEK 10< DAY 47 - 8 June 2010 (Tuesday)

Continue work...

-Remove the connecting rod bearing cap
-Remove the lube oil pipe on the right side
-Lift out piston and connecting rod
-Relocate all connecting rod and piston to the GF4 station workshop
-Arrange manpower from Lemal to take cylinder head, fuel pump and fuel injector back to Lemal
-Cleaning outer part of the engine
-Remove inlet and outlet cap of the tube oil cooler
-Take back cylinder head, fuel pump and fuel injector to Lemal

>WEEK 10< DAY 46 - 7 June 2010 (Monday)

Before start the work, listen safety briefing by station and get Permit to Work (PTW)...
Request to the station to provide scaffolding for dismantling exhaust manifold..


Start work:
-remove rocker arm cover, rocker arm, push rod, inspection door and fuel pump..
-perform crankcase deflection..
-remove fuel pipes, purging pipes and fuel injector..
-drain coolant
-remove exhaust manifold
-remove cylinder head on the left side (no 1-9)
-remove cylinder head on the right side (10-18)
-drain the lube oil

>WEEK 10< DAY 45 - 6 June 2010 (Sunday)

Mobilize manpower and tools to Stesen Janaelektrik Sultan Salahuddin Abdul Aziz, Kapar Energy Venture (KEV), Kapar Selangor...The project are dismantling and inspection of the black start diesel engine generator..

As I know, the engine is GMT BL 230.18 from Italy with the capacity 800kW (18 cylinder)

6 staffs and I will go to this overhaul project...Departure from base Lemal at 10 am an arrive at 8 pm...

>WEEK 9< DAY 44 - 3 June 2010 (Thursday)

Continue yesterday work...
We must change the alternator charger to confirm that the engine can run..Fortunately, we bring one other alternator charger...The work to change this alternator charger a bit complicated...We must remove the pulley first...

After the pulley connected back, the new alternator charger put back in it's place...The engine start back and it's can run very well...The work done...

At the evening packing all tools and go back to Lemal...

>WEEK 9< DAY 43 - 2 June 2010 (Wednesday)

After breakfast, quickly go to Kg Lubok Batu..From Ceneh Baharu, it's take 30 minutes to reach...At Kg Lubok Batu, it's only have 5 or 6 family...
When we reached, a generator set already there...The genset supply electricity since the engine can't function...
The engine for this station is the LISTER..Only at Kg Lubok Batu have this engine...This engine have to start by hand..Abg Jamal, who's expert about the engine check what's the problem...The engine have a lightning struck during heavy rain last week.....The problem maybe voltage control unit (VCU) or alternator charger...
Firstly, we change the VCU..2 VCU replaced with old one..But the engine still can't run..As a final decision, we must change the alternator charger...

>WEEK 9< DAY 42 - 1 June 2010 (Tuesday)

Received a call from a staff at TNB Ceneh Baharu, Chukai, Terengganu....He told that a engine at Kg Lubok Batu have a problem...The engine cannot run...So, he wants a team sent to repair the engine...

After received approval from supervisors, a team must go to the Lubok Batu...3 staffs, one training student and I prepare all the tools...

We departed at 5 pm...The traveling from Pasir Mas to Bandar Ceneh Baharu takes 5 hours...We arrive at 11 pm..We all sleep at TNB Ceneh Baharu...

>WEEK 9< DAY 41 - 31 May 2010 (Monday)

Yesterday work is still not completed...The driver for this generator set want to change the position of the exhaust...So, we must cut the exhaust and weld the exhaust with other position...

Then, we change one old ammeter with the new ammeter...After complete the welding...we put back the exhaust...The work done...

>WEEK 9< DAY 40 - 30 May 2010 (Sunday)

One staff from TNB Temerloh come to Lemal to sent a generator set to be repaired...As usual, the engine for this genset is Deutz engine...The capacity for this engine is 32kW...The problem is the engine can't fully supply voltage...

Supervisor asked three skilled staff to check the engine and repaired it...Firstly, we supply load to the engine.This step we use to see what's the problem with this engine...After we supply the load, we found the problem...Maybe switch tripping or the engine supply overload voltage....

>WEEK 8< DAY 39 - 27 May 2010 (Thursday)

-Did work to make gasket for cooling water outlet cook, inlet manifold and cover cylinder head...
-Packing all the components with plastic to prevent from dirt...
-Work delay due to lack of spare part
-Check the tools and store it..
-Prepare all tools and get ready to back

>WEEK 8< DAY 38 - 26 May 2010 (Wednesday)

-Start clean cylinder head and cylinder block from soil carbon, rust and oil...
-Use wire brush to remove carbon on the surface of the valve at cylinder head...
-Clean the rocker arm, push rod, and cover push rod (8 units)
-Clean cooling water outlet cook (8 units)

>WEEK 8< DAY 37 - 25 May 2010 (Tuesday)

Continue work...

-Open bolt and nut at exhaust manifold and inlet manifold...
-Remove rocker arm, push rod and tappet from cylinder head...
-Open cylinder head nut using socket box and open cylinder jacket using handy pump...Both open with hydraulic pressure between 600 to 700 kgf/cm^3
-Successful take out 7 units of cylinder head with kren...
-Do inspection to cylinder head and found that O ring broken because overheating...

>WEEK 8< DAY 36 - 24 May 2010 (Monday)

Before we start work, staff SJSI brief we all a little bit about safety..

-First, we do test running at the black start diesel engine no 1 to ensure what is the problem...
-Detecting 7 water leakage between cylinder head and block engine at side A...
-Take all meter reading when test running..
-Start work with open the cylinder head cover and open the fuel and oil piping (8 units)

>WEEK 8< DAY 35 - 23 May 2010 (Sunday)

As usual...Weekly meeting...

New job...Last week, supervisor received a call from officer Stesen Janakuasa Sultan Ismail (SJSI), Paka..He want a team sent to repair Daihatsu engine model 8DV-32

After prepared all tools, 4 staffs and I move to SJSI Paka. Arrived at 5 pm...

>WEEK 7< DAY 34 - 20 May 2010 (Thursday)

At the morning, check again the engine..All work completed...Prepared all tolls and get ready to go back...

Go back to Lemal at 10 am and arrived at 4.30 pm...

>WEEK 7< DAY 33 - 19 May 2010 (Wednesday)

Continued yesterday work...

To remove the fuel pump, we must used special tools...We must measure the special tools area with vernier..Then, go to workshop and make circular steel plate using lathe machine...After all done, the fuel pump that can't be opened can be opened..

>WEEK 7< DAY 32 - 18 May 2010 (Tuesday)

Woke up early...Start the work...First, we service Caterpillar set no 1...The problem for set no 1 is the engine can't be started...So, we identify the problems...Check the load at the battery...Check the starter whether it function or not...Then, we opened the fuel pump and identify the problem..

>WEEK 7< DAY 31 - 17 May 2010 (Monday)

Today is the traveling day to go to Connaught Bridge power station...Last week, the officer from connaught bridge called and want a team send to repair the engine..He want to service 2 set of Caterpillar engine...

After prepared all the tolls, 3 staffs and I moved from Lemal at 10 a.m to connaught bridge...The journey takes 9 hours..We all stopped at 4 or 5 places to rest..We arrived at connaught bridge at 7.45 pm...

Two staffs were waiting for us...We all slept at the quarters....

>WEEK 7< DAY 30 - 16 May 2010 (Sunday)

Morning meeting...
-Discussed the completed works and uncompleted works...
-Discussed about audit that will come next week..

Supervisor call me to help him...He want to build a rack to put engine component...Previously, all the components just put in the box...Now, we want to put in the rack to showed they are arranged..

>WEEK 6< DAY 29 - 13 May 2010 (Thursday)

Continue installation after know a little bit about the gap...The purpose to know the gap is to facilitate the installation in correct way..

Step of work...
- place the thin knot on the piston for bumping test
- put cylinder head
- put air manifold
- tighten the cylinder head
- turn the flywheel two times
- open air manifold
- open cylinder head

>WEEK 6< DAY 28 - 12 May 2010 (Wednesday)

Installation of header filter...
First, we must know the gap...There are 3 gap before we install the header filter which is piston gap, ring gap and ring groove...
1. Piston gap
-gap between piston and linear (0.40 mm)

2. Ring gap
-top ring (o.45 mm). used for compression
-intermediate ring (1.00 mm). ued for compression
-oil ring (0.50 mm). used to prevent oil from rising to the
combustion chamber

3. Ring groove
-top ring (0.10 mm)
-intermediate ring (0.08 mm)
-oil ring (0.05 mm)

>WEEK 6< DAY 27 - 11 May 2010 (Tuesday)

Identify the cause of engine problems..Especially, the use of starter..

Step of work:
* supply the energy to the starter, if no response, check the battery
voltage and check the supply at the terminal battery...Lastly, if the
starter not function, new starter must be changed...

*starter not rotate..the step we should take are, check the battery
voltage and its connection...If, not function again, new starter must be
changed...