International Islamic University Malaysia Engineering industrial training (Eit 4004)

OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

Name: Matric No: Discipline: Department: Visiting Lecturer: Training Period: Year: Mohd Affizul Ariff Bin Salim (0710841) Bachelor of Mechanical Automotive Engineering Mechanical Dr Mirghani 12th April 2010 2nd July 2010 2010

MOHD AFFIZUL ARIFF BIN SALIM

0710841

COMPANY VERIFICATION STATEMENT

I hereby declared that, MOHD AFFIZUL ARIFF BIN SALIM (Matric No: 0710841) student of DEPARTMENT OF MECHANICAL ENGINEERING, International Islamic University Malaysia (IIUM) has successfully completed his Engineering Industrial Training from 12th April 2010 till 2nd July 2010 at OMNI OIL TECHNOLOGIES (ASIA) SDN BHD under Quality Control Department and Engineering Department. This report is prepared by above-mentioned student as a partial fulfillment of this training. All information given in this report is true and does not contain any confidential information or classified data that might in a way or another abuse the companys policies

Approved by,

Mr. Zulkiflee Samsi Manufacturing Engineer act as Plant Manager OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

(i)
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

MOHD AFFIZUL ARIFF BIN SALIM

0710841

ACKNOWLEDGEMENT

In the name of ALLAH, the Most Gracious and Most Merciful, I thank ALLAH SWT for bestowing me with health, knowledge, patience and determination to complete the Engineering Industrial Training at OMNI OIL TECHNOLOGIES (ASIA) SDN BHD. Therefore, I acknowledge with great gratitude to Engineering Department and Quality Control department of OMNI OIL TECHNOLOGIES (ASIA) SDN BHD, which supervised by Mr. Zulkiflee Samsi and Mr. Hanafi Mamat for willingness to train me, giving advices, sharing experiences, and giving encouragement to me. Biggest appreciation to Quality Control Inspector, Mr. Md Shah and Mr. Yazid Sabarani for continuously supporting and providing me with all great lessons and valuable experiences during the time I was in the company. Acknowledgement also to Mr. Hisham Serry act as Production Engineer for his kindness and for treating me nicely and equally like other permanent staffs in OMNI OIL TECHNOLOGIES (ASIA) SDN BHD. Millions appreciation goes to all staffs, engineers, senior technicians and technicians for sharing their knowledge and for welcoming me to be part of OMNI OIL TENOLOGIES member. Also I would like to express my greatest appreciation to my visiting lecturer Dr MIrghani for his consultation and advice to complete my final presentation and report and also for the assessment throughout this engineering industrial training. Special thank goes to my colleagues, Bro Khairul Muhaimin who always helped and support to solve all engineering work throughout the training process. Finally, my highest appreciation goes to my beloved parents for the moral support and encouragement to fulfill successfully this engineering industrial training.

(ii)

OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

MOHD AFFIZUL ARIFF BIN SALIM

0710841

SUMMARY
This Engineering Industrial Training report is prepared for the purpose of fulfilling the final requirement upon completion of the EIT program which had been underwent during semester 3, 2009/2010 session. This report contains all the relevant information and description regarding the training program which has been successfully completed at OMNI OIL TECHNOLOGIES (ASIA) SDN BHD. It also discusses the activities and contribution towards the company throughout the training program period. There were no specific projects assigned to the students, instead the students were placed to various section within the company such as Quality Control Department section Assembly Department section and Engineering Department section. Any tasks given are subjected to the supervision of personnel of each section. This Engineering Industrial Training is beneficial for the students since it will enhance their knowledge regarding engineering work throughout the practical training. During the training, it helps the student to build up their level of confidence as well as how to respect other peoples such as technician or engineer. It is a platform for the students to be more adaptable to real working environment and to develop as well as to enhance their interpersonal skills. More over it can develop the skills, ability, and competency of the students throughout this industrial training.

(iii)

OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

MOHD AFFIZUL ARIFF BIN SALIM

0710841

BACKGROUND OF OMNI OIL TECHNOLOGIES

Omni Oil Technologies is the first leading edge integrated technology development and manufacturing center that was set up in the Middle East early 2004 for drilling tools for the Oil and Gas industry. It is conveniently based in Dubai prominent Free Zone, Jebel Ali, United Arab Emirates. Omni oil is capable of developing, modifying and producing customized tools to deal with even the most extreme down holes challenges. Omni currently operates throughout the Middle East and North Africa in major oilfield centers such as Saudi Arabia, U.A.E., Oman, Kuwait, Egypt and Sudan. A larger manufacturing facility for OMNI is currently under construction in Jebel Ali Free Zone in order to face up to the increased demand for OMNI products. In addition, another manufacturing center is under establishment in Malaysia to cover the Asia Pacific market needs.

We are committed to excellence in standards and quality control and providing unmatched local support, says Mr. Mohammad Makhlouf, the President/CEO of the company. All OMNI products adhere to API standards and are assured through a quality management system in accordance with ISO-9001 2000. All OMNI tools are designed and analyzed using leading edge technologies in design and stress analysis using Finite Element Analysis (FEA) computer simulation packages. The manufacturing facility is equipped with Computer Numerically Controlled (CNC) production lines, delivering precisions manufacturing to the highest worldwide standards.

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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

MOHD AFFIZUL ARIFF BIN SALIM

0710841

MISSION AND VISION OF OMNI OIL TECHNOLOGIES

To create a product development and manufacturing organization that serves the oil and gas industry in the Middle East and grows profitably and independently into the global markets in an environmentally friendly manner while maximizing value to its shareholders and surrounding community and become the preferred organization of choice to its employees and customers To provide a training and development platform for emerging regional human capital and place the region on the front end of technical innovation and development in the global oil and gas industry To become the leading global technology development and manufacturing organization in the oil and gas industry originating from the Middle East

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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

MOHD AFFIZUL ARIFF BIN SALIM

0710841

PRODUCT OF OMNI OIL TECHNOLOGIES

OMNI Oil Technologies is an approved supplier of Drilling Enhancement Tools for the major national oil companies through the Middle East. OMNI Drilling Enhancement Tools are deployed in many locations and in a variety of different formation lithologies around the region. Furthermore, these tools have shown outstanding performance in total operating hours. OMNI Oil Technologies Drilling Enhancement Tools are compatible with any BHA configuration thereby improving the overall drilling performance in well bores of all sizes. OMNI's current products are branded as the Bassal generation of products after their chief designer, Mr. Adel Bassal. OMNI products are classified into three groups:

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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

MOHD AFFIZUL ARIFF BIN SALIM

0710841

OBJECTIVES OF ENGINEERING INDUSTRIAL TRAINING

To provide student with industrial working environment To provide students with job experience To assist students to acquire knowledge related to Oil and Gas industry, and company Administration Systems.

To assist student to gain informal learning process regarding engineering studies

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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

MOHD AFFIZUL ARIFF BIN SALIM

0710841

ROLES DURING ENGINEERING INDUSTRIAL TRAINING

Join Quality Control Department on 12th April 2010 1st week to be familiar with all measuring tools and equipment in QC department such as Holtest, Digital Calliper, Vernier Calliper, Rotary work plug, Rotary work ring, Block Gauge, Dial Gauge and others. 2nd week to be able to measure threading for different bodies such as flexi joint 6.5 inches and flexi joint 8.00 inches also for roller reamer 17.5 inches. There different types of threading which are 4 Internal Flush Threading, 6 5/8 Regular Threading, 7 5/8 Regular Threading. The threading measurement done by using thread height gauge, rotary work plug, rotary work ring, bore gauge, outer micrometer, thread profile 4 1/2 IF, 6 5/8 REG, 7 5/8 REG, API Gauge, Lead gauge and others. Also measure the diameter of flexi joint 8.00 inches and 6.75 inches. 3rd week Do the quality file for flexi Joint 8.00 inches and 6.75 inches. In this quality file, it includes inspection standard, inspection test plan (bubble drawing), Inspection check sheet, Drawing A3 size and also the NCR report. Before the inspection check sheet is done, must refer to the drawing to check the tolerance for each parameter and also check the bubble drawing parameter 4th week - Check the flexi joint again with brother Shah to confirm the length dimension by using the Big Milling Centre 3 (BMC 3) machine. This due to the accuracy of measurement by using the BMC 3 is higher rather than by using measuring tape. The measurement by using BMC 3 machine is up to 3 decimal points rather than using tape measure which is up to only 2 decimal points. With BMC 3 machine also we can check the straightness and roundness of the flexi joint. 5th week Check the dimension of RR Pin since it cannot be assembles with the RR cutter. Do the measurement for the diameter of the RR Pin and all the dimension are within the tolerance. Then, carry out the straightness check for RR Pin at the Granite table by using the Filler Gauge. Then only we can detect the straightness problem which is around 50 micron.

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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

MOHD AFFIZUL ARIFF BIN SALIM

0710841

6th week Do the length measurement for driver sub 10 inches and driver sub tapered 7.5 inches with brother shah. Also check the straightness and roundness of driver sub 10 inches and driver sub tapered 7.5. Also check the surface roughness at the machining site for mandrel upper and mandrel lower. Regarding the measurement of radius which is difficult to be measured, brother shah and me do the testing by using the silicon putty and put the silicon putty at the designated area so that the radius can be measured by using CMM machine. 7th week Do the inspection check sheet of mandrel upper and mandrel lower, also the inspection standard for mandrel upper and mandrel lower, with the inspection test plan (bubble drawing) and the original drawing for mandrel upper and mandrel lower. Do the inspection check sheet of driver sub, also the inspection standard, the inspection test plan (bubble drawing) and the original drawing for mandrel upper and mandrel lower. Revise the flexi joint check sheet, inspection test plan (bubble drawing), inspection standard and the original drawing A3 size. The entire documents are in soft copy form. 8th week Do the checking and inspection for the quality controls equipment such as outer micrometer, rotary work plug and rotary work ring. This due to the existence of corrosion at the surface of the equipment and need to be removed from the surface. Also do the checking for all equipments serial numbers and do the marking of the serial number at all equipments. 9th week Do the inspection for upper block and lower block with bro Yazid and identify the incomplete inspection for upper block and lower block. There are 2 batches which consist of 24 pieces. Also do the packing for cutter, upper block, and lower block and pin to be sent for nitriding process. 10th week Join Assembly Process Department on 8th June 2010. Do the assembly process between tungsten carbide insert and cutter. Do the hardness test for the heat treated jig with Bro Halim. Do the assembly process for cartridge, which consist of upper block, lower block and cutter.

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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

MOHD AFFIZUL ARIFF BIN SALIM

0710841

11th week Do assembly process for cutter and pin with piston, spring and oil ring. Then do the assembly for cartridge, which consist of upper block, lower block and cutter. Do inspection for raw material which given from the supplier. Need to confirm the dimension such as diameter and length. 12th week Visit to Umetoko Company in Kota Kemuning Shah Alam to see the nitriding process. Preparation of final presentation slide and also final report on Engineering Industrial Training

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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

MOHD AFFIZUL ARIFF BIN SALIM

0710841

MANUFACTURING PROCESS
The word manufacturing is derived from the Latin manu factus, meaning made by hand. The word manufacture first appeared in 1567 and the word manufacturing appeared in 1683. The word product and production first appeared sometime during the 15th century. The word manufacturing and production often are used interchangeably. For any manufacturing company such as OMNI OIL TECHNOLOGIES (ASIA) SDN BHD, manufacturing is generally a complex activity involving a wide variety of resources such as: Product design Machinery and tooling Process planning Materials Purchasing Manufacturing Production control Support services Marketing Sales Shipping Customer service

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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

MOHD AFFIZUL ARIFF BIN SALIM

0710841

MANUFACTURING PROCESS AT OMNI OIL TECHNOLOGIES

Raw material

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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

MOHD AFFIZUL ARIFF BIN SALIM

0710841

Equipment (CNC BIG TURNING CENTER)

Equipment (CNC BIG MILLING CENTER)

Tools (Steady rest)

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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

MOHD AFFIZUL ARIFF BIN SALIM

0710841

Labor / Workforce

Waste (chips)

Rejected Product

Finished Product

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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

MOHD AFFIZUL ARIFF BIN SALIM

0710841

It is essential that manufacturing activities be responsive to several demands and trends:

1. Product must fully meet design requirement, product specification and standard 2. A product must be manufactured by the most economical and environmentally friendly methods 3. Quality must be build into the product at each stage, from design to assembly rather than relying on quality testing after the product is manufactured 4. In the highly competitive environment of today, production methods must be sufficiently flexible to respond changing market demands, types of products, production rates, production quantities, and provide on time delivery to customer. 5. Continuous developments in materials, production methods, and computer integration of both technological and managerial activities in a manufacturing organization must be evaluated constantly with a view to their appropriate, timely, and economical implementation 6. Manufacturing activities must be reviewed as a large system, all parts of which are interrelated to varying degrees. Such systems can now be modeled in order to study the effect of factors such as changes in market demands, product design, materials, and production methods on product quality and cost. 7. The manufacturer must work with customer for timely feedback for continuous product improvement. 8. A manufacturing organization constantly must strive for higher levels of productivity, defined as the optimum use of all its resources such as materials, machines, energy, capital, labor, and technology; output per employee per hour in phase must be maximized.

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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

MOHD AFFIZUL ARIFF BIN SALIM

0710841

SELECTION OF MATERIAL
Selection of material

Properties of material

Cost and availability

Appearance, service life and recycling The appearance of materials, after they have been manufactured into products, influences their appeal to the consumer. Color, feel and surface texture are characteristics that we all consider when marking a decision about purchasing a particular product.

The first consideration is the mechanical properties of the material such as strength, toughness, ductility, hardness, elasticity, fatigue and creep. The next consideration is the physical properties of the material such as density, specific heat, thermal expansion, thermal conductivity, melting points, and electrical and magnetic properties. A combination of mechanical and physical properties is the strength to weight and stiffness to weight ratios of the material, particularly important aerospace, automotive and petroleum industry. Chemical properties play an important part such as oxidation, corrosion, general degradation, toxicity and flammability. Manufacturing properties of material whether it can be cast, formed, machined, joined, and heat treated, with relative ease.

The economic aspects of material selection are also important as technological consideration of the properties and characteristic of material. If raw materials or manufactured component are not available in desired shapes, dimension, and quantities, hence additional processing will be required and this situation will lead to increase in the production cost.

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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

MOHD AFFIZUL ARIFF BIN SALIM

0710841

BEHAVIOUR AND MANUFACTURING PROPERTIES OF MATERIAL

Behavior and manufacturing properties of materials

Structure of materials
-Atomic bond: Metallic, covalent and ionic -Crystalline -Amorphous -Partly Crystalline -Polymer Chains

Mechanical properties

Physical and Chemical properties

-Density -Melting Point -Specific Heat -Thermal Conductivity -Thermal Expansion -Electrical Conductivity -Magnetic Property -Oxidation -Corrosion

Property modification

-Strength -Ductility -Elasticity -Hardness -Fatigue -Creep -Toughness -Fracture

-Heat Treatment -Precipitation Hardening -Annealing -Tempering -Surface Treatment -Alloying -Reinforcement -Composites -Laminations -Fillers

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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

MOHD AFFIZUL ARIFF BIN SALIM

0710841

HEAT TREATMENT PROCESS

The properties and behavior of metal and alloy during manufacturing and performance during their service life depend on their composition, structure, processing history and as well as heat treatment process to which they have been subjected. The important properties such as strength, hardness, ductility, toughness and resistance to wear are influenced greatly by alloying elements and heat treatment process. By doing heat treatment processes it can modifies the microstructures and change the mechanical properties such as formability, machinability, hardness, toughness and strength. As for OMNI OIL TECHNOLOGIES (ASIA), the implementation of heat treatment process is done for the purpose of hardening the jigs which is used for machining process and quality inspection process.
FLAME JIG

As shown in the picture, it is during the heating process of the jig. The required temperature is about 800 C and the increment of the temperature is measured by using the temperature sensor.

COOLANT

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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

MOHD AFFIZUL ARIFF BIN SALIM

0710841

After about 3 hours heating the jig, thus the temperature reaches 800 C. So after that we need to immediately immerse the jig inside the coolant. This is rapid cooling process since we desired the properties of the jig to be very hard as compared to initial properties of the jig. This process is known as quenching process.

There are 7 different cooling processes which are: Quenching This is the process in which the heated material is being rapidly cooled by using water, oil, coolant or other cooling liquid as a medium of cooling. By doing quenching process, it has great rate of cooling and instantaneously the heated material will be in the normal temperature again. The property of the material differ from the untreated material such as increase in hardness value, become brittle, increase in strength and toughness value and not uniform grain structure (Formation of martensite microstructure) Normalizing This is the process in which the heated material is cooled down in the open air in the room temperature. By doing normalizing process, it has better rate of cooling as compared to annealing process and the will be in the normal temperature again for about 4 to 5 hours. The property of the material will be different than the untreated material such as slightly increase in hardness value, increase in ductility, and slightly increase in strength and toughness value, and also slightly uniform grain structure (Formation of partly martensite and partly pearlite microstructure). The normalizing process also is done to refine the grain boundaries.

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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

MOHD AFFIZUL ARIFF BIN SALIM

0710841

Annealing This is the process in which the heated material is cooled down very slowly inside the heating furnace. By doing annealing process, it has the lowest cooling rate as compared to the normalizing process and quenching process. The material will be in the normal temperature again for about 1 day after the heating process is done. The property of the material will differ than the untreated material in term of the hardness since annealing process will have the lowest hardness value than quenching and normalizing process. The other property which differs is the ductility in which the annealed material will be very ductile. Furthermore, the annealed material will have less strength and toughness value. The annealed material also will have very fine and uniform grain structure. (Formation of pearlite microstructure)

Tampering In tempering process the material is heated to a specific temperature (depend on the composition of the material) and it is cooled down under prescribed rate of cooling. Tempering process is used to reduce brittleness, increase ductility and toughness and reduce the residual stress.

Austempering In austempering process, the heated material is quenched rapidly from the austenitizing temperature to avoid formation of ferrite and pearlite microstructure. It is then held at a certain temperature until isothermal transformation from austenite to bainite microstructure is complete. It is then cooled down to room temperature. Austempering process is used to substitute the conventional quenching and tempering in which to reduce the tendency toward cracking, and distortion during quenching, to improve ductility and toughness while maintaining hardness value.

Martempering In martempering process, the heated material is first quenched from austenitizing temperature in a hot fluid medium such as hot oil or molten salt. Then it is held at that temperature until the temperature is uniform throughout the material, and being cooled at moderate rate such as in air. Martempered material has fewer tendencies to crack, distort, or develop residual stress during heat treatment process. (17)

OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

MOHD AFFIZUL ARIFF BIN SALIM

0710841

Ausforming In ausforming process the material is formed into desired shapes within controlled ranges of temperature and time to avoid formation of nonmartensitic transformation product. The part is then cooled at various rates to obtain the desired microstructures. Ausformed material has superior mechanical properties.

To clearly see the different microstructures such as pearlite, bainite, ferrite and martensite, it can be visualize through microscope and electron microscope.

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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

MOHD AFFIZUL ARIFF BIN SALIM

0710841

SURFACE TREATMENTS AND COATINGS

After the part is manufactured, some of its surfaces may have to be processed further in order to ensure certain properties and characteristics. It may be necessary to perform surface treatments in order to:

Improve resistance to wear, erosion, and indentation Control friction (sliding surfaces of tools, dies, bearings, and machine ways) Reduce adhesion (electrical contact) Improve lubrication Improve resistance to corrosion and oxidation Improve fatigue resistance Rebuild surfaces Modify surface textures Impart decorative features

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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

MOHD AFFIZUL ARIFF BIN SALIM

0710841

(1) Mechanical Surface Treatment

Shot Peening Process

Shot peening surface

In shot peening the workpiece surface is impacted repeatedly with a large number of cast steel, glass, or ceramic shot (small ball), which make overlapping indentation on the surface. This action causes plastic surface deformation at depths up to 1.25 mm using shot sizes that ranges from 0.125 to 5 mm in diameter. Because of the plastic deformation is not uniform, throughout the parts thickness, shot peening causes compressive residual stresses on the surface, thus improving the fatigue life of the component by delaying fatigue crack initiation. Unless the process parameters are controlled properly, the plastic deformation of the surface can be so severe that it can damage the surface. However it should be noted that (if these parts are subjected to high temperature) the residual stress will begin to relax (thermal relaxation) and their beneficial effects will be diminished greatly.

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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

MOHD AFFIZUL ARIFF BIN SALIM

0710841

(2) Case Hardening

Nitriding Process

Methods of case hardening are such as carburizing, carbonitriding, cyaniding, nitriding, flame hardening, and induction hardening. Case hardening as well as some of other surface treatment processes induces residual stresses on the surface of the material. The formation of martensite microstructure during case hardening causes compressive residual stresses on surface. Such stresses are desirable since it will improve the fatigue life of the component by delaying the initiation of fatigue crack. As the engineering industrial training (EIT) conducted at OMNI OIL TECHNOOGIES (ASIA) SDN BHD, the case hardening process also already implemented to improve the fatigue life of the material such as roller reamer. The case hardening process that being used is nitriding. Nitriding is a heat treating process that alloys nitrogen into the surface of a metal to create a case hardened surface. It is predominantly used on steel but also titanium, aluminum and molybdenum. The processes are named after the medium used to donate nitrogen. The three main methods used are: Gas nitriding Salt bath nitriding Plasma nitriding

Before nitriding process (surface are shining)

After nitriding process (surface are slightly darker)

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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

MOHD AFFIZUL ARIFF BIN SALIM

0710841

Gas Nitriding

In gas nitriding the donor is nitrogen rich gas usually ammonia (NH3), which is why it is sometimes known as ammonia nitriding. When ammonia comes into contact with the heated work piece it disassociates into nitrogen and hydrogen. The nitrogen then diffuses from the surface into the core of the material.

The advantages of gas nitriding are: All round nitriding effect Large batch sizes possible With modern computer control of the atmosphere the nitriding result can be tightly controlled Relative cheap equipment cost

The disadvantages of gas nitriding are: Reaction kinetics heavily influenced by surface condition Surface activation is sometimes required to successfully treat with a high chromium content Ammonia as nitriding medium (toxicity which is harmful when inhaled in large quantities and when there is presence of oxygen there is risk of explosion)

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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

MOHD AFFIZUL ARIFF BIN SALIM

0710841

Salt Bath Nitriding In salt bath nitriding the nitrogen donating medium is a nitrogen containing salt such as cyanide salt. The salt used also donates carbon to the workpiece surface making salt bath a nitrocarburizing process. The temperature used is typical of all nitrocarburizing processes 550590 C The advantages of salt bath nitriding are: Quick processing time Simple operation

The disadvantages of gas nitriding are: The salt used are highly toxic Only one process possible with a particular salt type Plasma Nitriding Plasma nitriding also known as ion nitriding, plasma ion nitriding, or glow discharge is an industrial surface hardening treatment for metallic materials. There is hot plasma, typified by plasma jets used for metal cutting, welding, cladding or spraying. There is also cold plasma usually generated inside vacuum chambers at low pressure regimes. Here high temperature characteristics of the ionized gases are not used, but the electronic properties become useful. Thus an ionized gas like nitrogen in such a low pressure regime becomes much more reactive. The advantages of plasma nitriding are: Close control of the nitride microstructure Allowing nitriding with or without compound layer formation Performance of metal parts get enhance Working lifespan gets boosted Strain limit and fatigue strength are being treated (23)

OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

MOHD AFFIZUL ARIFF BIN SALIM

0710841

(3) Conversion coatings

Phosphate conversion coating

Conversion coating is the process of producing a coating that forms on metal surfaces as a result of chemical or electrochemical reactions. Various metals can be conversion coated such as steel, aluminum, and zinc. Oxides that naturally form on their surfaces are a form of conversion coating. Usually phosphate coatings are used on steel part for corrosion resistance, lubricity or as a foundation for subsequent coating or painting. Semi finish area at OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

Phosphate coating at the 12.25 inches Roller Reamer body

The application of phosphate coating make use of phosphoric acid and takes advantages of the low solubility of phosphates in medium or high pH solution. Iron, zinc, or manganese phosphate salt are dissolved into solution of phosphoric acid. When steel are placed in the phosphoric acid metal reaction takes place which locally depletes the hydroxonium ions, raising the pH and causing the dissolved salt to fall out of the solution and be precipitated on the surface. The acid and metal reaction also creates iron phosphate locally which may also be deposited. In the case of depositing zinc phosphate or manganese phosphate the additional iron phosphate is frequently an undesirable addition to the coating.

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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

MOHD AFFIZUL ARIFF BIN SALIM

0710841

Surface of material after phospating

Surface of material before phospating

Typical phosphate procedures: (1) Cleaning the surface (2) Rinsing (3) Surface activation (4) Phosphating (5) Rinsing (6) Neutralizing rinse (7) Drying (8) Application of supplement coating

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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

MOHD AFFIZUL ARIFF BIN SALIM

0710841

(4) Hard Facing

In this process a relatively thick layer, edge, or point of wear resistance hard metal is deposited on the workpiece surface using the fusion welding techniques. Numerous layers can be deposited to repair worn part. Hard facing enhances wear resistance of the material, hence such material are used in the manufacture of tools, dies and various industrial components. Worn part also can be hard faces for extended use.

This is the surface whereby the hard facing process is conducted

The picture before hard facing process is done.

The picture after hard facing process is done.

Stress concentration initiated

During hard facing process

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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

MOHD AFFIZUL ARIFF BIN SALIM

0710841

STRESS CONCENTRATION
The torsion formula (shear stress) max = Tc / J, whereby T is torsion, c is the outer radius and J is the polar moment of inertia. This formula can be applied to regions of a shaft having circular cross section that is constant or tapers slightly. When sudden changes arise in the cross section, both the shear stress and shear strain distribution in the shaft become complex and can be obtained only by using experimental methods or possibly by a mathematical analysis based on the theory of elasticity. In order to eliminate the necessity for the engineer to perform a complex stress analysis, the maximum shear stress can be determined for a specified geometry using a torsional stress concentration factor, K. As in the case of axially loaded members, K is usually taken from the value of graph. To use this graph, first we must determine the geometric ratio D/d to define the appropriate curve and then once the abscissa r/d is calculated, the value of K is found along the ordinate. The maximum shear stress is then determined from the equation:

max = KTc / J

It can be noted from the graph that an increase in fillet radius, r causes a decrease in K. Hence the maximum shear stress can be reduced by increasing the fillet radius. Also if the diameter of the material is reduced, the ratio D/d will be lower and so the value of K and therefore max will be lower. Like the case of axially loaded member, torsional stress concentration factors should always be used when designing part or material that will be subjected to fatigue or cyclic torsional loadings. These conditions give rise to the formation of cracks at the stress concentration, and this often lead to sudden failure of the part or material. Thus it is necessary to strengthen the region which has stress concentration though hardening process such as hard facing. (27)
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

MOHD AFFIZUL ARIFF BIN SALIM

0710841

r D d

Ratio: D/d

Ratio: r/d

Stress concentration section

Stress concentration in material occurs at point of sudden cross sectional change, such as couplings, keyways and at shoulder fillets. The more severe change the larger the stress concentration. As for the design analysis it is not necessary to know the exact shear stress distribution on the cross section. Instead it is possible to obtain the maximum shear stress concentration factor, K which is determined through experiment and is only a function of the geometry of the material. Normally the stress concentration in a ductile material subjected to a static torque will not have to be considered in design. However if the material is brittle or subjected to fatigue loadings, thus stress concentration become important parameter. (28)
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

MOHD AFFIZUL ARIFF BIN SALIM

0710841

HARDNESS TEST
The hardness test is conducted to test the hardness of the material after the material undergoes the heat treatment process. As for the heat treatment process, it can alter the microstructure of the material as well as it can change the properties of the material. Thus hardness is one of the characteristics or properties that also changed after the heat treatment process is conducted.

Portable Brinell hardness Tester

Specimen

Pressure Lever

Proper way to use the Portable Brinell hardness Tester

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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

MOHD AFFIZUL ARIFF BIN SALIM

0710841

The impact diameter after hardness test is conducted

King Brinell Microscope

The impact diameter at the surface of the specimen is observe through the King Brinell Microscope

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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

MOHD AFFIZUL ARIFF BIN SALIM

0710841

Portable Brinell hardness table

Impact Diameter

Brinell hardness value

Rockwell hardness value

Tensile strength value

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PROCEDURE FOR USING BRINELL HARDNESS TESTER

1. Put the specimen at the Brinell hardness tester. 2. Assemble the Pressure Lever at the Portable Brinell hardness Tester. 3. Slowly apply force at the Pressure Lever until the indicator reach the value of 3000 kg. 4. Remove the specimen and observe the impact diameter at the surface of the specimen. 5. Observe the impact diameter through King Brinell Microscope 6. Compare the value of impact diameter with the portable Brinell hardness table.

After the hardness test is conducted then only we can compare the hardness value of untreated material with the heat treated material. The result shows that the hardness value increased as the material undergoes heat treatment process.

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ENGINEERING METROLOGY AND INSTRUMENTATION

Engineering Metrology is defined as the measurement dimensions such as length, thickness, diameter, taper, angle, flatness, profile, and others. Traditionally, measurement has been after the part has been produce (known as post-process inspection). The term inspection means checking the dimension of what has been produced or is being produced and determining whether it complies with the specified dimensional tolerances and other specification. However, for current situation, measurement is being made while the part is being produced on the machine known as in-process or on-line or real-time inspection. An important aspect of metrology in manufacturing processes is the dimensional tolerance. Tolerance is the permissible variation in the dimension of a part. Tolerance is important because of their impact on the proper functioning of a product, part interchangeability and manufacturing cost. Generally, the smaller the tolerance the higher are production costs. Numerous measuring instrument and devices are used in engineering metrology each of which has its own application, resolution, precision and other features. Two terms that commonly are used to describe the type and quality of an instrument are:Resolution- It is the smallest difference in dimension that the measuring instrument can detect or distinguish. Precision- It is the degree to which the instrument gives repeated measurements of the same standard. In Engineering Metrology, the word instrument and gage are used interchangeably. The temperature control is very important, particularly for making measurement with precision instruments. The standard measuring temperature is 20 C, and all gages are calibrated at this temperature. In the interest of accuracy, measurement should be taken in controlled environments which have the tolerance 0.3 C.

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GEOMETRIC FEATURE OF PART AND PRODUCT

The most common quantities and geometric features that typically are measured in engineering practice and products made by the manufacturing processes as described: Length including all linear dimension part Diameter outside and inside, including part with different outside and inside diameter (steps) Roundness including out-of-roundness, concentricity, and eccentricity Depth such as drilled or bored holes and cavities in dies and molds Straightness such as shafts, bars and tubing Flatness such as machined and ground surfaces Parallelism such as two shafts and slide ways in machine Perpendicularity such as threaded bar inserted into a flat plate Angle including internal and external angles Profile such as curvatures in castings, forgings, and car bodies

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GENERAL CHARACTERISTICS AND SELECTION OF MEASURING INSTRUMENTS

The characteristics and quality of measuring instruments generally are described by various specific terms such as:-

Accuracy The degree of agreement of the measured dimension with true value Amplification See magnification Calibration Setting of instrument to give reading that are accurate according reference standard Drift See stability Linearity The accuracy of reading of instrument over its full working range Magnification The ratio of instrument output to the input dimension Precision Degree to which instrument gives repeated measurement of same standard Repeat accuracy The same as accuracy but repeat many times Resolution Smallest dimension that can be read on instrument Rule of 10 An instrument or gage should be 10 times more accurate than the dimensional tolerances of the part being measured Sensitivity Smallest difference in dimension that an instrument can distinguish or detect Speed of response How rapidly an instrument indicates the measurement Stability An instruments capability to maintain its calibration over period of time

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MEASURING TOOLS AND INSTRUMENTS

API External Taper Gauge

API Internal Taper Gauge

API Lead Gauge

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API Thread Height Gauge

API Thread Profile Gauge

API Thread Height Gauge Setting

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API Thread Lead Gauge Setting

Rotary Ring Work Plug

Rotary Pin Work Plug

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Ring Gauge

Portable Brinell Hardness Tester

Torque Wrench

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Steel Ruler

Outer Micrometer

3 Point Holtest

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Feeler Gauge

Bore Gauge

Angle Protractor

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Vernier Caliper

Digital Caliper

Depth Caliper

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Height Gauge

Surface Roughness Tester

Tape Measures

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Master Gauges

Silicon Putty

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QUALITY CONTROL, QUALITY ASSURANCE AND INSPECTION

As the product is manufactured, there are 2 characteristic which can observe at the product or part. The 2 characteristics are external characteristic and internal characteristic. External characteristic most commonly involve dimensions, size, and surface finish and also integrity issues such as surface damage from cutting tools or friction during the processing of the workpiece. Internal characteristics include defects, such as porosity, impurities, inclusion, phase transformation, embrittlement, cracks, debonding of laminations and residual stress. Some of these defects may exist in the original stocks, and some are introduced or induced during machining or other manufacturing process operation. Before the manufactured products are marketed, the products need to be inspected for several characteristics. This is very important since to: Ensure dimensional accuracy so that the parts properly fits into other components during assembly process Identify the products whose failure or malfunction has potentially serious implications, such as bodily injury or fatality.

The prevention of defects in products and on-line inspection of part are the major goals in all manufacturing activities. Product quality always has been one of the most important aspects of manufacturing operation. If the product has poor quality, thus it will result toward: Difficulties in assembling process and maintaining component Result in the need for in-field repair Have significant build-in-cost of customer dissatisfaction

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QUALITY CONTROL'S JOB SCOPE

To do inspection process of the manufactured product at Omni Oil Technologies To prepare the check sheet all manufactured product at Omni Oil Technologies To prepare inspection standard of all manufactured product at Omni Oil Technologies To prepare inspection test plan (bubble drawing) of all manufactured product at Omni Oil Technologies

QUALITY MANAGEMENT SYSTEM (QMS)

Original drawing A-3 size Inspection test plan Inspection standard Inspection check sheet Out sourcing Need conformation report (NCR)

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INSPECTION PROCESS

Post-process inspection
The quality control inspectors do the post process inspection for the manufactured product

In-process inspection
The quality control inspectors need to inspect the semi finish manufactured product at the CNC milling machine

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The outer diameter inspection by using outer micrometer

The total length inspection by using tape measure

The length inspection by using height gauge

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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD

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The angle inspection by using angle protractor

The inner diameter inspection by using holtest

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ASSEMBLY PROCESS
Assembly process is the process whereby the individual parts and components produced by manufacturing processes are assembled into finished products by various methods. In OMNI OIL TECHNOLOGIES (ASIA) SDN BHD, the manual assembly process is used to assemble the manufactured product. Manual assembly use simple tools and generally is economical for small lot. Because of dexterity of the human hand and fingers and their capability of feedback through various senses, worker can manually assemble even complex part without much difficulty. Human hand is capable of doing this simple operation with relative ease.

TCI

Cutter

The assembly process between Cutter and Tungsten Carbide Insert (TCI)

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Block

Block, Pin and Cutter are assembled together

Pin

Complete assembled Cartridge

Cutter

After the Cartridge is completely assembled, it is then to be assembled with Roller Reamer body

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Roller Reamer Body The Pocket at the Roller Reamer Body

After the assembly process between the Cartridge and Roller Reamer Body

The assembly process is done by using Torque wrench

The complete assembled Roller Reamer Body

There are 3 Pockets for each Roller Reamer Body

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DESIGNING PROCESS
Before any product is manufactured, firstly we need to design the product. To design a product, we can use computer-aided design (CAD) which involves the use of computer to create design drawings and products models. In OMNI OIL TECHNOLOGIES (ASIA) SDN BHD, the implementation of SOLID WORKS is very useful to design any product. Once we receive the drawing from customer, then we need to make it in 3-D representation by using SOLID WORKS. There is other software such as CATIA (computer aided three dimensional interactive application). The design can be subjected to engineering analysis and can identify potential problem such as excessive load, deflection or interference at mating surface during assembly. Information such as list of material, specification and manufacturing instruction also included in CAD database. Thus the designer can analyze the manufacturing economics of alternative designs.

The design of the product in three dimensional representations

After the product is manufactured

The product of Halliburton Company (Flexi Joint)

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DESIGNS OF PRODUCT

Flexi Joint Design

Driver Sub Design

AGS Mandrel Lower Design

AGS Mandrel Upper Design

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DESIGNS OF JIGS

Design of the jig to be used during assembly process between cutter and tungsten carbide insert

Design of the jig for outer diameter inspection

Design of the jig for inner diameter inspection

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PROBLEMS AND DIFFICULTIES

ASSEMBLY DIFFICULTIES:Before the assembly process is done, the inspection process need to be done first to ensure all the parameters are within the tolerance Even if all parameters are within test plan (bubble drawing) tolerance but the part cannot be assembled properly due to: Straightness problem Roundness problem

Straightness

Roundness

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MEASUREMENT DIFFICULTIES:1. Difficulties to measure the radius value Measured by using silicon putty and coordinate measuring machine (CMM)

2. Difficulties to measure total length of the body Measured by using big milling centre 3 (BMC-3) rather than using tape measure since the machine coordinate is more accurate and more precise

3. Difficulties to measure the inner diameter of the body Measured by using jig

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LESSON AND EXPERIENCED LEARNED

Engineering Industrial Training is very essential to all students since it will provide the student with knowledge and experience regarding engineering discipline. Throughout 12 weeks Engineering Industrial Training, it help me a lot in term of discipline, time management, the ethics at work, practicing health and safety procedures, and most importantly how to adapt with the real working environment as well as how to tackle the problems. Furthermore, this Engineering Industrial Training enhances my communication skills effectively since the interaction between different kinds of people in various situations. It teaches me the proper way to mingle with my supervisor and senior technicians. In fact, all the staffs at OMNI OIL TECHNOLOGIES are very friendly and they give me a full cooperation in order to accomplish the job assigned to me. For me, the main objectives of Engineering Industrial Training which is to expose the students to the real working environment, to learn how to handle and working with various engineering equipments, getting familiar with the ethics at work, and how to deal with difficult situation regarding engineering discipline, has been achieved. The students were given the opportunity to deals with hands-on-experience and a place to apply related engineering theory which already learned in university. Lastly, OMNI OIL TECHNOLOGIES is a good place to have industrial training since it can provide student with related engineering studies as well as it can build up the engineering attitude for the student benefits.

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SUGGESTION AND RECOMMENDATION

During Engineering Industrial Training, it is brilliant way for the students to gain knowledge and industrial experience. The Engineering Industrial Training is essential since it will enable the students to face challenge in real working environment and yet can provide exposure to the students. As for university future implantation of Engineering Industrial Training program, it is suggested that the duration should be more than 12 weeks. Instead of 3 months or 12 weeks Engineering Industrial Training, the Kuliyyah of Engineering should conduct the industrial training to be for about at least for 4 to 6 months. As far as this matter is concern, most of the companies require the industrial training to be for about 4 to 6 months. This is because during the Engineering Industrial Training, most of the companies assigned the students with certain project which need to be complete at the end of the industrial training. Hence, if the student only have short period of time, the students cannot completely solve the projects within the time provided. Furthermore, for the industrial company, it is wise and suggested to have proper plan for the practical students. This is due to students can learn more on the things that had to be done during the practical training. It is also recommended for the company to send the industrial trainee to various departments accordingly in order to familiarize the students with whole working process.

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CONCLUSION
As conclusion, Engineering Industrial Training has provided the student with real exposure of industrial environment. After 12 weeks of industrial training, there are so many experiences that have been gained such as what is quality control job description, how the company manages their worker, how to deal with difficult task and how to solve it and many others. During Engineering Industrial Training, it can help the student to get clear view about real life engineering situation whereby all the workers are dedicated to solve any task related to engineering discipline. Some of the knowledge may not be learned from the books or in lecture but it can be learned through Engineering Industrial Training. Analytical and critical thinking skills are very important to make a good decision. Book may tell the facts and the truth but may not teach the way to solve every problem in real life situation. Besides the technical skills, trainees will also learn to improve their communication skills and how to develop good character. This is because to build up a good relationship, one must have a good attitude and characteristic. An engineer may be the superior of the technician but if the characteristic and attitude showed by the engineer is bad, the technician or the people who work with the engineer may not respect the engineer as their superior. So that is why the proper attitude and characteristics need to be developed. Lastly, the students is eventually turned to be more mature and independent as they complete the Engineering Industrial Training since the projects or activities conducted require the student to be more proactive. As the result, the students will be equipped more in term of technical part as well as attitude and characteristics part to be future engineer. Insyallah.

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REFERENCES
Wikipedia hardening process Mechanics of Materials (seventh edition) by R. C. Hibbeler Manufacturing Engineering Technology (fifth edition in SI unit) by Serope Kalpakjian and Steven Schmid Umetoko (Malaysia) Sdn Bhd pamphlet Omni Oil Technologies (Asia) Sdn Bhd Omni sealed bearing roller reamer inspection and maintenance manual Mr. Zulkiflee Samsi (Manufacturing Engineer act as Plant manager Omni Oil Technologies) 06-799 6203 Mr. Hanafi Mamat (Quality Control Supervisor Omni Oil Technologies) 06-799 6203

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APPENDIX A

OMNI OIL TECHNOLOGIES (ASIA) SDN BHD