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ACKNOWLEDGEMENT
Alhamdulillah, praise to be to Allah S.W.T with is milling and blessing, I have done successfully publish the final report of Industrial Training in the duration.
First of all, thanks you so much to the General Manager of Sultan Ismail Power Station , Tuan Hj Mohamad Bin Che Jusoh because give me an opportunity to done my industrial training in this station. Also to the supervisor of Quality and Training department, Pn. Norita Akma Bt Mohd Nor, Sheikh Zaki, Mr. Silva Raajoo and not forgetting to the senior foreman of Boiler Maintenance Section, En. Mat Azan and senior foreman of Gas Turbine Maintenance Section, Tn. Hj. Ariffin as my mentor.
Thank you also to my lecturers, engineers, foreman, technician, and fitters that gave me support during my industrial training in Boiler Maintenance Section and Gas Turbine Maintenance Section. Also to all trainees, thanks a lot for helping me during this training.
Lastly, special thanks to my beloved parents and family because give me support to undergo my training at SJSI. Above all, I would like to express a lot of thankfulness to my entire companion for your kindness helping me in difficulty.
i
ABSTRACT
For the twenty weeks I have undergo my industrial training at Sultan Ismail Power Station (SJSI) in Paka, Terengganu. SJSI Paka was accredited ISO 9000:2001 and ISO 14000 and the latest accreditation is OHSAS 18001:2007. As the biggest combined cycle power plant in Malaysia, SJSI Paka operates using combined cycle system with 8 units of gas turbine, 8 units of waste heat boilers, and 4 units of steam turbine. The overall power generated from this combination was 1200MW with efficiency 46%. In a combined cycle mode, the electricity is produced by a composition of gas turbine, waste heat boilers, and steam turbine. In a gas turbine, atmosphere air has drawn in a pressurized through various stages of compressor blades then the compressed air mix with fuel and burn in combustion chamber. The result, hot gases from combustion chamber with high velocity expended through the turbine blades. The rotating turbine drives the generator to produce electricity. In open cycle mode, the gas turbine release exhaust gas to atmosphere through blast start, thus wasting the heat energy contains. In combined cycle operation, the exhaust gas is diverted by a damper system to waste heat boiler. The heat from the exhaust is exchange to the water in the boiler to produce steam. The boiler is design to produces steam in two different pressures, which is high pressure and low pressure superheated steam. The resulting superheated steam brought to common steam delivery manifold of the low pressure and high pressure steam respectively before admission into the steam turbine. In steam turbine, the steam is expanding through the turbine blade and nozzle arrangement. The expansion of steam produced rotating effect to the turbine, which is couple to generator to produce electricity. The used steam exhausted into the condenser is condensed (cooled) by means of seawater. The condensate is pump back to the feed water tank. The water from the feed water tank is circulated through the boiler and heated again for the next continuous cycle.
ii
TABLE OF COTENTS
CHAPTER
1
TOPIC
PAGE
ORGANIZATION PROSPECTUS
1.1
Tenaga Nasional Berhad Corporate Profile
1
1.2
Vision and Mission
4
1.3
Sultan Ismail Power Station, Paka
5
1.3.1
Brief Description of Company
5
1.3.2
Location Selection
5
1.3.3
Plant Description
7
1.3.4
Phase 1 Project
8
1.3.5
Phase 2 Project
9
1.3.6
Gas Turbine
10
1.3.7
Waste Heat Recovery Boiler
11
1.3.8
Steam Turbine
12
1.3.9
Electrical System
13
1.3.10
Operational Aspect
13
1.3.11
Plant Safety
13
1.3.12
Environmental Aspect
14
1.3.13
The Process of Producing Electricity
15
1.3.14
Technical Data 1.3.14.1
Phase 1 (Combined Cycle)
17
1.3.14.2
Phase 2 (Combined Cycle)
19
iii
2
GAS TURBINE 2.0
Introduction
21
2.1
GTMS Organization Charts
22
2.2
Gas Turbine Operation
23
2.3
Major Component of Gas Turbine
24
2.3.1
Compressor
25
2.3.1.1
Compressor Rotor
25
2.3.1.2
Compressor Stator
26
2.3.2
2.3.3
2.3.4
2.3.5
3
Combustion Chamber
31
2.3.2.1
Combustion Wrapper
34
2.3.2.2
Combustion Chamber
34
2.3.2.3
Transition Pieces
34
2.3.2.4
Spark Plug
35
2.3.2.5
Flame Detector
35
2.3.2.6
Fuel Nozzles
35
Turbine
36
2.3.3.1
Turbine Rotor
37
2.3.3.2
Turbine Stator
41
Exhaust
42
2.3.4.1
Exhaust Frame
42
2.3.4.2
Exhaust Diffuser
44
2.3.4.3
Exhaust Plenum, Ducts and Silencers
45
Bearing
46
WASTE HEAT BOILER 3.0
Definition
48
3.1
Introduction
48
3.2
BMS Organization Chart
49
3.3
Design
50
3.4
Boiler Specification
50
3.5
Waste Heat Boiler Operation
51
3.6
Low Pressure Water-Steam Circuit
53
3.7
High Pressure Water-Steam Circuit
55
iv
3.8
4
Major Component of Waste Heat Boiler
57
3.8.1
LP Economiser and Recirculating Pump
57
3.8.2
LP Drum
59
3.8.3
LP Vaporiser Circulating Pump
62
3.8.4
LP Superheater
63
3.8.5
HP Economiser
65
3.8.6
HP Drum
66
3.8.7
HP Vaporiser and Circulating Pumps
68
3.8.8
HP Superhaeter
69
3.8.9
Waste Heat Boiler Drains
71
3.8.10
Safety Valve
71
3.8.11
Exhaust Gas System
72
3.8.12
Phosphate Dosing System (LP & HP Drum)
74
TRAINING ACTIVITES 4.0
Scope of Task Activities in Training
76
4.1
Maintenance
79
4.1.1
Maintenance Inspection
79
4.2.2
Maintenance Schedule
80
4.2
Pump Maintenance
81
4.2.1
Alignment of the Pump
84
4.2.2
Pump Test Run
88
4.3
Overhaul Booster Pump
90
4.4
Service Main Oil Hydraulic Pump
93
4.5
Non-Destructive Testing
95
4.5.1
Liquid/Dye Penetrant Testing
96
4.5.2
Basic Step of Liquid Penetrant Testing
96
4.5.3
Type of Penetrant and Penetrant System
99
4.5.3.1
Type of Penetrant
99
4.5.3.2
Penetrant System
100
4.5.3.4
Solvent-Removable System
100
4.6
Assignment
102
4.6.1
102
Trace out Line for Cooling Water System
v
4.6.2
5
Trace out Line for Gas Fuel Forwarding Skid
105
4.6.2.1
Primary Separator
105
4.6.2.2
Secondary Separator
106
4.7
Procurement Process
108
4.8
5’s Activity
109
4.8.1
109
5’s in Brief
CONCLUSION
111
vi
LIST OF TABLES
TABLE NUM.
TITLE
PAGE
3.0
Specification Waste Heat Boiler Phase 1
50
3.1
Specification Waste Heat Boiler Phase 2
50
3.2
Operating Conditions of Waste Heat Boiler
52
4.0
Maintenance Schedule
80
4.1
Pump Test Run Result
89
vii
LIST OF FIGURES
FIGURE NUM.
TITLE
PAGE
1.0
TNB Power Plant in Peninsular Malaysia
3
1.1
Plant Layout
6
1.2
Sultan Ismail Power Station Phase 1
8
1.3
Sultan Ismail Power Station Phase 2
9
1.4
Gas Turbine Hall
10
1.5
Waste Heat Boiler Phase 1
11
1.6
Steam Turbine Hall
12
1.7
Diagram of Combine Cycle Block Flow
15
2.0
Organisation Structure of GTMS
22
2.1
Cutaway View of Gas Turbine Major Assemblies
24
2.3
Compressor Stator
26
2.4
Air Compressor Intake
27
2.5
Compressor Stator Blades Arrangement-Stages 1 to 10
28
2.6
Compressor Stator Blades Arrangement-Stages 11 to 17
30
& Exit Guide Vane 1&2 2.7
Combustion Chambers Arrangement
32
2.8
Combustion Chamber Details and Flow Diagram
33
2.9
Turbine Section
37
2.10
Turbine Bucket
38
2.11
Turbine Rotor Assembly
39
2.12
First Stage Air Cooled Bucket
40
2.13
Exhaust Frame Assembly
43
2.14
Exhaust Diffuser
44
viii
2.15
Arrangement Exhaust Ducts
45
2.16
No.1 Bearing in inlet Casing Assembly
46
2.17
No.2 Bearing Assembly
47
3.0
Schematic Diagram of Low Pressure Circuit
54
3.1
Schematic Diagram of High Pressure Circuit
56
3.2
LP Economiser
59
3.3
Sectional View of LP Drum
61
3.4
LP Vaporiser
63
3.5
LP Superheater
64
3.6
HP Economiser
66
3.7
Sectional View of HP Drum
67
3.8
HP Vaporiser
69
3.9
HP Superheater
70
3.10
Sectional View of Exhaust Gas System
74
4.0
Arrangement of the Pump and Motor
81
4.1
The Pump Body
81
4.2
Sequence for tighten bolts gland cover and casing pump
83
4.3
Laser Alignment Tools
84
4.4
Arrangement during Laser Alignment
85
4.5
Bearing housing of HP Feedwater Pump
86
4.6
Alignment of the Rotating Element
88
4.7
Assembly of Ball Bearing
88
4.8
Booster Pump
91
4.9
Disassemble Part of Booster Pump
92
4.10
Main Hydraulic Oil Pump
94
4.11
Safety Relief Valve
94
4.12
Basic steps of Liquid Penetrant Testing
96
ix
LIST OF ABBREVIATIONS AND SYMBOLS
RM
Ringgit Malaysia
TNB
Tenaga Nasional Berhad
TNBG
Tenaga Nasional Berhad (Generation)
TNBD
Tenaga Nasional Berhad (Distribution)
SJSI
Stesen Janaeletrik Sultan Ismail
MW
Mega Watt
WHB
Waste Heat Boiler
kV
Kilo Volt
DEO
Department of Environment
dB
Decibel
GT
Gas Turbine
ST
Steam Turbine
LP
Low Pressure
HP
High Pressure
AC
Alternating Current
DC
Direct Current
MJ
Mega Joule
°C
Degree Celsius
NA
Not Available
GTMS
Gas Turbine Maintenance Section
BMS
Boiler Maintenance Section
IGV
Inlet Guide Vane
MHOP
Main Hydraulic Oil Pump
NDT
Non-Destructive Testing
CW
Cooling Water
UTeM
Universiti Teknikal Malaysia Melaka x
Alhamdulillah, praise to be to Allah S.W.T with is milling and blessing, I have done successfully publish the final report of Industrial Training in the duration.
First of all, thanks you so much to the General Manager of Sultan Ismail Power Station , Tuan Hj Mohamad Bin Che Jusoh because give me an opportunity to done my industrial training in this station. Also to the supervisor of Quality and Training department, Pn. Norita Akma Bt Mohd Nor, Sheikh Zaki, Mr. Silva Raajoo and not forgetting to the senior foreman of Boiler Maintenance Section, En. Mat Azan and senior foreman of Gas Turbine Maintenance Section, Tn. Hj. Ariffin as my mentor.
Thank you also to my lecturers, engineers, foreman, technician, and fitters that gave me support during my industrial training in Boiler Maintenance Section and Gas Turbine Maintenance Section. Also to all trainees, thanks a lot for helping me during this training.
Lastly, special thanks to my beloved parents and family because give me support to undergo my training at SJSI. Above all, I would like to express a lot of thankfulness to my entire companion for your kindness helping me in difficulty.
i
ABSTRACT
For the twenty weeks I have undergo my industrial training at Sultan Ismail Power Station (SJSI) in Paka, Terengganu. SJSI Paka was accredited ISO 9000:2001 and ISO 14000 and the latest accreditation is OHSAS 18001:2007. As the biggest combined cycle power plant in Malaysia, SJSI Paka operates using combined cycle system with 8 units of gas turbine, 8 units of waste heat boilers, and 4 units of steam turbine. The overall power generated from this combination was 1200MW with efficiency 46%. In a combined cycle mode, the electricity is produced by a composition of gas turbine, waste heat boilers, and steam turbine. In a gas turbine, atmosphere air has drawn in a pressurized through various stages of compressor blades then the compressed air mix with fuel and burn in combustion chamber. The result, hot gases from combustion chamber with high velocity expended through the turbine blades. The rotating turbine drives the generator to produce electricity. In open cycle mode, the gas turbine release exhaust gas to atmosphere through blast start, thus wasting the heat energy contains. In combined cycle operation, the exhaust gas is diverted by a damper system to waste heat boiler. The heat from the exhaust is exchange to the water in the boiler to produce steam. The boiler is design to produces steam in two different pressures, which is high pressure and low pressure superheated steam. The resulting superheated steam brought to common steam delivery manifold of the low pressure and high pressure steam respectively before admission into the steam turbine. In steam turbine, the steam is expanding through the turbine blade and nozzle arrangement. The expansion of steam produced rotating effect to the turbine, which is couple to generator to produce electricity. The used steam exhausted into the condenser is condensed (cooled) by means of seawater. The condensate is pump back to the feed water tank. The water from the feed water tank is circulated through the boiler and heated again for the next continuous cycle.
ii
TABLE OF COTENTS
CHAPTER
1
TOPIC
PAGE
ORGANIZATION PROSPECTUS
1.1
Tenaga Nasional Berhad Corporate Profile
1
1.2
Vision and Mission
4
1.3
Sultan Ismail Power Station, Paka
5
1.3.1
Brief Description of Company
5
1.3.2
Location Selection
5
1.3.3
Plant Description
7
1.3.4
Phase 1 Project
8
1.3.5
Phase 2 Project
9
1.3.6
Gas Turbine
10
1.3.7
Waste Heat Recovery Boiler
11
1.3.8
Steam Turbine
12
1.3.9
Electrical System
13
1.3.10
Operational Aspect
13
1.3.11
Plant Safety
13
1.3.12
Environmental Aspect
14
1.3.13
The Process of Producing Electricity
15
1.3.14
Technical Data 1.3.14.1
Phase 1 (Combined Cycle)
17
1.3.14.2
Phase 2 (Combined Cycle)
19
iii
2
GAS TURBINE 2.0
Introduction
21
2.1
GTMS Organization Charts
22
2.2
Gas Turbine Operation
23
2.3
Major Component of Gas Turbine
24
2.3.1
Compressor
25
2.3.1.1
Compressor Rotor
25
2.3.1.2
Compressor Stator
26
2.3.2
2.3.3
2.3.4
2.3.5
3
Combustion Chamber
31
2.3.2.1
Combustion Wrapper
34
2.3.2.2
Combustion Chamber
34
2.3.2.3
Transition Pieces
34
2.3.2.4
Spark Plug
35
2.3.2.5
Flame Detector
35
2.3.2.6
Fuel Nozzles
35
Turbine
36
2.3.3.1
Turbine Rotor
37
2.3.3.2
Turbine Stator
41
Exhaust
42
2.3.4.1
Exhaust Frame
42
2.3.4.2
Exhaust Diffuser
44
2.3.4.3
Exhaust Plenum, Ducts and Silencers
45
Bearing
46
WASTE HEAT BOILER 3.0
Definition
48
3.1
Introduction
48
3.2
BMS Organization Chart
49
3.3
Design
50
3.4
Boiler Specification
50
3.5
Waste Heat Boiler Operation
51
3.6
Low Pressure Water-Steam Circuit
53
3.7
High Pressure Water-Steam Circuit
55
iv
3.8
4
Major Component of Waste Heat Boiler
57
3.8.1
LP Economiser and Recirculating Pump
57
3.8.2
LP Drum
59
3.8.3
LP Vaporiser Circulating Pump
62
3.8.4
LP Superheater
63
3.8.5
HP Economiser
65
3.8.6
HP Drum
66
3.8.7
HP Vaporiser and Circulating Pumps
68
3.8.8
HP Superhaeter
69
3.8.9
Waste Heat Boiler Drains
71
3.8.10
Safety Valve
71
3.8.11
Exhaust Gas System
72
3.8.12
Phosphate Dosing System (LP & HP Drum)
74
TRAINING ACTIVITES 4.0
Scope of Task Activities in Training
76
4.1
Maintenance
79
4.1.1
Maintenance Inspection
79
4.2.2
Maintenance Schedule
80
4.2
Pump Maintenance
81
4.2.1
Alignment of the Pump
84
4.2.2
Pump Test Run
88
4.3
Overhaul Booster Pump
90
4.4
Service Main Oil Hydraulic Pump
93
4.5
Non-Destructive Testing
95
4.5.1
Liquid/Dye Penetrant Testing
96
4.5.2
Basic Step of Liquid Penetrant Testing
96
4.5.3
Type of Penetrant and Penetrant System
99
4.5.3.1
Type of Penetrant
99
4.5.3.2
Penetrant System
100
4.5.3.4
Solvent-Removable System
100
4.6
Assignment
102
4.6.1
102
Trace out Line for Cooling Water System
v
4.6.2
5
Trace out Line for Gas Fuel Forwarding Skid
105
4.6.2.1
Primary Separator
105
4.6.2.2
Secondary Separator
106
4.7
Procurement Process
108
4.8
5’s Activity
109
4.8.1
109
5’s in Brief
CONCLUSION
111
vi
LIST OF TABLES
TABLE NUM.
TITLE
PAGE
3.0
Specification Waste Heat Boiler Phase 1
50
3.1
Specification Waste Heat Boiler Phase 2
50
3.2
Operating Conditions of Waste Heat Boiler
52
4.0
Maintenance Schedule
80
4.1
Pump Test Run Result
89
vii
LIST OF FIGURES
FIGURE NUM.
TITLE
PAGE
1.0
TNB Power Plant in Peninsular Malaysia
3
1.1
Plant Layout
6
1.2
Sultan Ismail Power Station Phase 1
8
1.3
Sultan Ismail Power Station Phase 2
9
1.4
Gas Turbine Hall
10
1.5
Waste Heat Boiler Phase 1
11
1.6
Steam Turbine Hall
12
1.7
Diagram of Combine Cycle Block Flow
15
2.0
Organisation Structure of GTMS
22
2.1
Cutaway View of Gas Turbine Major Assemblies
24
2.3
Compressor Stator
26
2.4
Air Compressor Intake
27
2.5
Compressor Stator Blades Arrangement-Stages 1 to 10
28
2.6
Compressor Stator Blades Arrangement-Stages 11 to 17
30
& Exit Guide Vane 1&2 2.7
Combustion Chambers Arrangement
32
2.8
Combustion Chamber Details and Flow Diagram
33
2.9
Turbine Section
37
2.10
Turbine Bucket
38
2.11
Turbine Rotor Assembly
39
2.12
First Stage Air Cooled Bucket
40
2.13
Exhaust Frame Assembly
43
2.14
Exhaust Diffuser
44
viii
2.15
Arrangement Exhaust Ducts
45
2.16
No.1 Bearing in inlet Casing Assembly
46
2.17
No.2 Bearing Assembly
47
3.0
Schematic Diagram of Low Pressure Circuit
54
3.1
Schematic Diagram of High Pressure Circuit
56
3.2
LP Economiser
59
3.3
Sectional View of LP Drum
61
3.4
LP Vaporiser
63
3.5
LP Superheater
64
3.6
HP Economiser
66
3.7
Sectional View of HP Drum
67
3.8
HP Vaporiser
69
3.9
HP Superheater
70
3.10
Sectional View of Exhaust Gas System
74
4.0
Arrangement of the Pump and Motor
81
4.1
The Pump Body
81
4.2
Sequence for tighten bolts gland cover and casing pump
83
4.3
Laser Alignment Tools
84
4.4
Arrangement during Laser Alignment
85
4.5
Bearing housing of HP Feedwater Pump
86
4.6
Alignment of the Rotating Element
88
4.7
Assembly of Ball Bearing
88
4.8
Booster Pump
91
4.9
Disassemble Part of Booster Pump
92
4.10
Main Hydraulic Oil Pump
94
4.11
Safety Relief Valve
94
4.12
Basic steps of Liquid Penetrant Testing
96
ix
LIST OF ABBREVIATIONS AND SYMBOLS
RM
Ringgit Malaysia
TNB
Tenaga Nasional Berhad
TNBG
Tenaga Nasional Berhad (Generation)
TNBD
Tenaga Nasional Berhad (Distribution)
SJSI
Stesen Janaeletrik Sultan Ismail
MW
Mega Watt
WHB
Waste Heat Boiler
kV
Kilo Volt
DEO
Department of Environment
dB
Decibel
GT
Gas Turbine
ST
Steam Turbine
LP
Low Pressure
HP
High Pressure
AC
Alternating Current
DC
Direct Current
MJ
Mega Joule
°C
Degree Celsius
NA
Not Available
GTMS
Gas Turbine Maintenance Section
BMS
Boiler Maintenance Section
IGV
Inlet Guide Vane
MHOP
Main Hydraulic Oil Pump
NDT
Non-Destructive Testing
CW
Cooling Water
UTeM
Universiti Teknikal Malaysia Melaka x
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