Week 12, 25th June

A knowledge sharing session is conducted by Razak, electrical technician about the types of circuit breaker and its function. A circuit breaker is an automatically-operated electrical switch designed to protect an electrical circuit from damage caused by overload or short circuit. Its basic function is to detect a fault condition and, by interrupting continuity, to immediately discontinue electrical flow. Unlike a fuse, which operates once and then has to be replaced, a circuit breaker can be reset (either manually or automatically) to resume normal operation. Circuit breakers are made in varying sizes, from small devices that protect an individual household appliance up to large switchgear designed to protect high voltage circuits feeding an entire city.

Week 12, 23rd & 24th June

Mr. Suhaili (Safety & Security Executive) briefed us about the emergency preparation plan. Emergency and disaster planning is a basic necessity of every safety and control system. Safety boots and helmet is a must before entering the power station.

Week 12, 21st & 22nd June

Muridon (store keeper) explained the store management procedures to us. The purpose of store management is to ensure that all goods, materials, spare parts and fuel that are received by the station are checked, inspected, stored in the designated storage location and issued as and when required in accordance to the power station procedures.

Purchasing procedure is also explained to us so that we have the clear idea of how a stock is purchased.

Purchasing procedure

Week 11, 18th June

A knowledge sharing session is conducted by Tai Chin Wee and Zurain from CNI session. The presentation is about the basic instrumentation which is the art of measuring the value of plant parameter. The $ parameters are pressure, flow, level and temperature. The output signals are standard signal 4-20mA and 20-100kPa pneumatic signal.

Week11, 17th June

Silica, pH and conductivity tests are performed twice a day. Silica tests are performed using Silica Analyzer. If the silica content in the water is too high, bottom blowdown valve will open at the boiler drum. pH testr30 and HANNA conductivity meter are used to perform pH and conductivity test.

Week 11, 16th June

Yukhaimi took me to electrochlorination plant to gain further understanding about electrolysis. Inside electrolysis room, the electrolysis cell needed to be cleaned once a week using hydrochloric acid. The function of hydrochloric acid is to extract ion chlorine and the unwanted positive ions become insoluble substances.

For the electrolysis process, the seawater booster pump will pump the seawater to the strainer for filter purpose. The seawater then will undergo the electrolysis process and the gas hydrogen will stored in the degasifier tank.

Electrolysis process

Electrolysis Cell

Week 11, 15th June

The cation exchanger and anion exchanger needed to regen every 350m3 of usage while mixed bed exchanger is every 4500m3

The regeneration of the anion exchangers requires caustic soda (sodium hydroxide). During the regeneration, warm sodium hydroxide at 50’C is required; hence the regeneration water heater is used to supply demineralized water at 82’C to the water blender which provides 50’C water to the caustic dilution.

The regeneration of the cation exchangers requires sulfuric acid. The supply of 98% sulfuric acid is stored in demineralizer sulfuric acid storage tanks.

Cation exchanger, Anion exchanger and Mixwd Bed exchanger

Week 11, 14th June

Yukhaimi, chemical technician explained the process of demineralization to me.

Firstly, service water is fed to the carbon filter. The influent water is passed through a column of activated carbon to remove the major part of the organic matter and residual chlorine.

Then, the water is routed to the cation exchanger packed with a column of strong acid cation, exchange ion resin in the hydrogen form.
The cation effluent is then passed through a strong base anion inside the anion exchanger. The hydrogen ions from the cation resin neutralized the hydroxide ions from the anion resins and yield pure water.

The demineralized water is then passed to the mixed bed exchanger which contain a mixture of anion exchanger and cation exchanger to further polish the water before the water is discharged to demineralized water storage tank.

Demineralization process for the plant

Week 10, 11st June

In the evening, there is a knowledge sharing session conduct by Amer (mechanical technician). He shared his experience about overhauling shutoff gas valve with us. This work will be done once a year during the outage session. Before installing the valve, they need to measure the valve can sustain how much pressure. The minimum pressure is about 25bar.

Week 10, 10th June

As the process of turbine start up includes torque converter, I had been asked to find out the function of torque converter.

The heart of Voiths’ hydrodynamic torque converter is its hydraulic circuit; consisting of a pump, turbine, and a guide wheel with adjustable guide vanes. This is combined in a common housing filled with hydraulic oil.

The mechanical energy of the motor is converted into hydraulic energy through the pump wheel. In the turbine wheel the same hydraulic energy is converted back into mechanical energy and transmitted to the gas turbine/generator shaft.

The adjustable vanes of the guide wheel regulate the mass flow in the circuit. At closed guide vanes (small mass flow) the power transmission is at its minimum. With the guide vanes completely open (large mass flow), the power transmission is at its maximum.

Basic design hydrodynamic torque converter

Week 10, 9thJune

Azlan (SBO) explained the trend of turbine speed during the start up. Before the turbine can be fired and brought to operating speed, it must first be rotated or cranked by an motor, operating through a torque converter to provide the cranking torque and speed required by the turbine startup. After the cranking speed reach 25% of the full speed, the turbine will start purging.

The process of purging stop when the turbine speed drops to 9% of the full speed. The function of purging is to drain out all the combustable gas from combustion compartment until exhaust compartment.

The process of firing starts after the purging until the turbine speed reach full speed.

Turbine speed trend

Week 10, 7th@8th June

As the plant having audit for integrated management system, the staff told us that we at least must know the mission and vision of the company.

Vision – The group envisions itself to be a global player in the energy and energy related business.
Mission – the group’s mission is to enhance shareholder return.

For the Quality Policy & Objective of the plant, the group is committed to be efficient and responsible by ensuring high standards in Quality and achieve full customer’s satisfaction by making ‘Quality A Way of Life’.

Quality Policy & Objective

Week 9, 4th June

In the morning, I followed Awang (BO) to the roof of the control room to make air-condition changeover. Air conditioner for control room was changed from 1B to 1A.

From Nooter Eriksen Operating manual, I learnt that recirculation pump on HP and LP economizers are use to increase the inlet feedwater temperature. It is required during the distillate oil as fuel. Condensation of acid can occur and corrodes the tubes of economizer if the temperature is low.

Week 9, 3rd June

I and another staff, Leo checked the temperature of the inlet and outlet drain valve at HRSG as there is suspected leak at the drain valve. If the inlet and outlet temperature is difference, that mean there is leakage at the valve. We use the infrared thermometer to measure the temperature.

Week 9, 2nd June

Two lecturers, Syed Zahidul Islam and Azrul Ghazali came over for plant visits. After get to know our direct supervisor, they have a short meeting to discuss our progress during the industrial training.

Week 9, 1st June

I participated in the steam turbine auxiliaries weekly changeover. As last week I followed patrolman, this week I will be at control center room monitor the changeover. Abang Azmi, SBO, let me to handle the changeover work under his supervise. I need to communicate with Nazirin (BO) to make sure that every pump is function able when I activate the standby pump. Once the pump is running, then the running pump will be deactivated. This process is repeated for every changeover pump.

Week 9, 31st May

I followed abang Fadzli, patrolman to do the gas turbine auxiliaries changeover. Before the changeover begins, abang Fadzli take down the suction pressure discharge pressure abd the expansion tank level for cooling water pump. After the changeover, the readings also need to take down. The following changeover is continuing with turbine compartment ventilation fan and distillate forward pump.

Then, abang Fadzli brought us to activate online water wash to decrease the turbine temperature so that the load will increase.

Week 8, 27th May

I followed abang Azmin, patrolman to do the emergency diesel generator test run. Before the test run, the engine running hour, distillate meter reading need to take and the generator circuit breaker (52 DG) must be disconnected. After all the preparation had done, the test run begin. The test run last for about 20 minutes and accessories like exhaust temperature, lube oil level, air vessel pressure need to take after the test run. When the test run begin, the exhaust dark smoke density need to check every minute.

Abang Azmin is doing the EDG test run

Cooling tower for EDG system