Industrial Training Report

Industrial Training Report 2013
1.0 INTRODUCTION Industrial training is one of the requirements for an engineering students. It plays an important role for oneself to experience the real working environment in engineering aspect. I had undergone the industrial training program at Stesen Janaelektrik Sultan Ismail (SJSI) Paka for 10 weeks. During this period, I have learnt lots of extra knowledge in spite of all the curricular subjects that I have studied in university. I was assigned to the Chemical Services and Environmental Section under the Production Department with the supervision of Encik Mohammad bin Abdullah, the chemist of Chemical Services and Environmental Section. There are five main jobs for this section. It was responsible to carry out lab analysis either daily daily or periodically analysis. Sometimes it has to run analysis of samples from other TNB power plants. To date they are monitoring four plants: boiler, water treatment plant, electrochlorination plant, electrochlorintaion plant and waste water treatment plant in term of chemical dosing, plant performance and pollution control. If there are any oil spillages, pollutions or chemicals problems, this section will be responsible to handle them. In short, this section has the responsibility to monitor and maintain the environmental aspect of this station. This report covers the informations and experiences that I have gained from the industrial training program in SJSI Paka. These includes few routine activities of Chemical Services Section, environmental control monitoring and other activities in SJSI.

2.0 CONTENT 2.1 Organization Chart
Figure 2.0:Organization Chart of SJSI Paka 2.2 History of Company SJSI Paka is located in the State of Trenegganu approximately 100 km to the south of the state capital, Kuala Terengganu. It uses the principle of combined cycle. The total capacity of Tenaga Nasional for currently installed is about 1200 MW thus, make the station becomes the top 3 largest power plant after all. This power plant has two phases, phase 1 with a total capacity of 900 MW, consists of block 1, block 2 and block 3, and phase 2 with total capacity of 300 MW consists of block 4.

2.2.1 Phase 1 Phase 1 Combined Cycle Project utilizes the professional services from Mitusi/Alsthom, which is the consultancy company for power plants originate from France and Japan. The first combined cycle has been operated as weel as it was completely built on January 1986. Meanwhile block 2 and block 3 have been operated respectively on May and July 1986. Finally, the whole project completed by the end of 1986 with cost of RM 920 millions. 2.2.2 Phase 2 Phase 2 project was started on October 1990 costed RM 300 millions and operated as open cycle. The purpose of the phase 2 project is all about supporting the usage of power or in other words, the request of the power is increasing time by time. Otherwise, it was estimated that the usage of power might be rapidly increase in 1991. The first gas turbine for this second phase was operated since 17 September 1991 meanwhile the second gas turbine was operated since 29 September 1991. The combined cycle for phase 2 was started since July 1994. It was the forth combined cycle block and it could generate 100 MW power as well. Phase 2 project was finally completed and operated on 22 September 1997. 2.3 Process Flow 2.3.1 Process Flow of SJSI Paka There are four combined cycle blocks with capacity of 300 MW for each and could be functioning separately. All the blocks are controlled by a centralized control room. The first three blocks are in the phase 1 while the forth block is in the phase 2. Each combined cycle block consists of: 2 units of gas turbine (GT) with 100 MW capacity for each 2 units of waste heat boilers (WHB) I unit of steam turbine (ST) with 100 MW capacity for each Exhaust and black stack Control and monitoring system
Figure 2.1: Combined cycle block
Figure 2.2: Process flow of SJSI Paka
1) Outside fresh air is drawn into the combustion process through the fresh air intake. 2) The air is compressed into very high pressure. 3) Natural gas, the cleanest fossil fuel, is supplied to the combustor.

4) The combustor burns the natural gas as fuel with the compressed sir. This process causes the compressed air to expand significantly. The resulting hot gas/air mixture is directed to the expansion gas turbine. 5) The hot gas/air mixture causes the expansion gas turbine to rotate, which turns the turbine shaft. 6) The rotation of the turbine shaft drives the rotation of the generator, producing electricity. The air compressor is also driven by the turbine shaft. 7) The exhaust air/gas mixture from the expansion gas turbine is sent to the once-through steam generator (OSTG) to release its heat energy. 8) The heat in the exhaust is released in the once-through steam generator (OSTG) where the boiler feed water in the boiler tubes become high pressure, high temperature superheated steam. 9) The exhaust gas is released to the atmosphere through the exhaust stack. 10) Superheated steam is boiler feed water which has been heated to become high pressure, high temperature steam. 11) The superheadted steam is directed to the steam turbine which turns the turbine blades that turn the turbine shaft. 12) The rotating turbine shaft is connected to the generator, which is turned., producing electricity. 13) The electricity is sent through a transformer which steps up the voltage and moves it out to the electrical grid. 14) The electricity is transmitted along a series of wires for ultimate delivery to customers. 15) Seawater is circulated through the steam condenser as cooling system, where the steam in the steam pipes leaving the steam turbine is cooled back into water, so the water can be re-circulated back to the boiler as feed water to be heated into steam again. 2.3.2 Process Flow of Water Treatment Plant Water treatment plant is one of the divison of the chemical services and environmental section. The function of this plant is to produce demineralised water from supplied raw water by Syarikat Air Terengganu (SATU). Demineralized water will be used in the boiler to produce steam.
Figure 2.3: Process flow of Water Treatment Plant Raw water supplied by SATU will be sent to the splitter box where it will be divided into four flow in different pipes. These four flows of water then undergoes backwash to remove dirts in the integrated backwash storage (IBS). There are sand and antrasit in the IBS used to wash the water. Outflow of IBS will be sent to cation units where the positive charged ions will be removed. The removal of cations is done by resins IR 120 that act as ion exchanger. Carbon dioxide will be released in the degasser tower. Anion contained in the water will be removed in anion units. The resins used in anion units are IRA 458. The remaining cations and anions that pass by the cation and anion units will be removed in the mixed bed units. This is the final stage of producing demineralised water from raw water. And lastly, the demineralised water will be stored in the tank. 2.4 Daily Analysis The analysis actually is all about the water analysis. Every morning, the water samples will be taken from the boilers and so with the condensers from running blocks in the station where are located in phase 1 and phase 2. The water samples are taken in order to do the test in the laboratory and to determine the content in the water that might be harmful to the plant system. The tests conducted for the water samples are: Ammonia content in condenser and feedwater Silica and phosphate content in boiler drum pH and conductivity

2.4.1 Ammonia Test 2.4.1.1 Objective To determine the content of ammonia in feed water and condenser water. 2.4.1.2 Summary of Method This method is based on the Nesslers reagent, a strongly alkaline solution of potassium mercuric iodine. In the presence of ammonia, a reddish brown is formed. The intensity of this colour, which is porportional to the ammonia concentration, is measured by comparison with Lovibond permanent glass colour standards. 2.4.1.3 Apparatus Ammonia analyzer-Lovibond and standard comparator disc, Nessleriser glass tube
(a)
(b)
Figure 2.4: (a) Ammonia analyzer (b) Nesslerizer glass tube 2.4.1.4 Reagent Nessler reagent
Figure 2.5: Nessler reagent

2.4.1.5 Procedure 1. 50 ml of demineralised water is filled into the Nessleriser glass tube. 2. The demin water is placed in the left-hand compartment of the Lovibond comparator and treat this as blank. 3. 50 ml of water samples is filled into each glass tube and labelled. 4. 2 ml Nessler Reafent is added into every single glass tube contained water samples. 5. Stand the Nessleriser before a standard source of white light and compare the colour produced in the test solution with the colour in the standard ammonia disc, rotating the disc until a colour match is obtained. 2.4.2 Silica Test 2.4.2.1 Objective To determine silica content in water. 2.4.2.2 Summary of Method This method is based on the reaction of the soluble silica with molybate ion to form a greenish yellow complex which in turn is converted to a blue complex by redustion with 1-amino-2naphtol-4-sulphuric acid (A.N.S.A) solution. The intensity of the blue colour is proportional to the concentration of soluble silica present. Only reactive silica is detective by this method, while the un-reactive silica ones cannot be detective. 2.4.2.3 Apparatus 100ml volumetric flask, UV vis spectrometer, pipette 2.4.2.4 Reagent Ammonium molybdate, tartaric acid solution, A.N.S.A solution

2.4.2.5 Procedure 1. Measure 50ml of demin water as blank and 50ml of samples into 100ml polypropylene volumetric flasks. 2. Add 10ml of ammonium molybdate reagent and mix. Allow to stand for 10 minutes. 3. Add 10ml of tartaric acid reagent and mix. Stand for 5 minutes. 4. Add 2ml of A.N.S.A solution, mix and stand for 5 minutes. 5. Add demin water up to 100ml and mix. 6. Allow the solutions to stand for 15 minutes for colour development. 7. Zero the concentration reading by using blank solution. 8. Measure the absorbances of the solution using the spectrometer nad read the concentration of silica in ppm from the meter screen. 2.4.3 Phosphate Test 2.4.3.1 Objective To determine phosphate content in water. 2.4.3.2 Summary of Method This method is baesd on the reaction of the soluble silica with molybate ion to form a greenish yellow complex which in turn is converted to a blue complex by redustion with A.N.S.A solution. The intensity of the blue colour is proportional to the concentration of soluble silica present. Only reactive silica is detective by this method, while the un-reactive silica ones cannot be detective. 2.4.3.3 Apparatus 100ml volumetric flask, UV vis spectrometer, pipette 2.4.3.4 Reagent Ammonium molybdate, tartaric acid solution, A.N.S.A solution

2.4.3.5 Procedure 1. Measure 50ml of demin water as blank and 50ml of samples into 100ml polypropylene volumetric flasks. 2. Add 5ml of ammonium molybdate reagent and mix. Allow to stand for 10 minutes. 3. Add 2ml of A.N.S.A solution, mix and stand for 5 minutes. 4. Add demin water up to 100ml and mix. 5. Allow the solutions to stand for 15 minutes for colour development. 6. Zero the concentration reading by using blank solution. 7. Measure the absorbances of the solution using the spectrometer nad read the concentration of silica in ppm from the meter screen.
(a)
(b)
(c)
Figure 2.6: (a) UV vis spectrometer (b) reagent for silica test (c) reagent for phosphate test 2.4.4 pH Test 2.4.4.1 Objective To measure the pH value of water samples. 2.4.4.2 Summary of Method The pH meter and associated electrodes are standardized against two reference buffer solutions that closely bracket and anticipated sample pH. The sample measurement is made under strictly controlled conditions and prescribed techniques. The accuracy of this method depends largely on the buffer solutions and its calibration. 2.4.4.3 Apparatus A pH meter consisting of a potentiometer, an electrode, a reference electrode and a temperature compensating device.
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2.4.4.5 Procedure 1. The water samples are cooled to room temperature. 2. The sample is poured into a clean 100 ml polyethylene beaker and rinse the electrode with the sample. 3. Establish the equilibrium between electrodes and water samples by stirring the sample to ensure homogenity. 4. The pH of the water sample is read from the pH meter after 1 minute. 2.4.5 Conductivity Test 2.4.5.1 Objective To measure the conductivity of water samples. 2.4.5.2 Apparatus Conductivity meter 2.4.5.5 Procedure 1. The water samples are cooled to room temperature. 2. The sample is poured into a clean 100 ml polyethylene beaker and rinse the electrode with the sample. 3. Establish the equilibrium between electrodes and water samples by stirring the sample to ensure homogenity. 4. The conductivity of the water sample is read from the conductivity meter after 1 minute.
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(a)
(b)
(c)
Figure 2.7: (a) pH meter (b) conductivity meter (c) electrode 2.5 Fortnightly Analysis Fortnightly analysis is an analysis for raw water, steam and gas turbine water and cooling water. The parameters that have been monitored in fortnightly analysis are as follow: pH and conductivity silica and phosphate content total hardness calcium hardness total alkalinity zinc and copper content
the procedures for pH, conductivity, silica and phosphate analysis are the same with previous in daily analysis section. While the procedures of total hardness, calcium hardness and total alkalinity will be described in this section. 2.5.1 Total Hardness Test 2.5.1.1 Objective To determine total hardness of water samples
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2.5.1.2 Sumary of Method Calcium and magnesium ions react with disodium ethylenediaminetetra acetate (EDTA) to form a complex solution. The end point of the reaction is detected by means of a total hardness indicator. It will change from violet (purple) to blue colour, when the reaction is completed. 2.5.1.3 Apparatus White porcelain casserole, measuring cylinder, burette 2.5.1.4 Reagent EDTA N/50 solution, ammonium buffer soltuion, BDH total hardness indicator tablet 2.5.1.5 Procedure 1. measure 100 ml of water sample in a white porcelain casserole. 2. Add 2 ml of ammonium buffer solution. 3. Add 1 BDH total hardness tablet indicator and break it to dissolve. 4. Titrate with N/50 EDTA solution. 5. The end point is reached when the last trace of violet/red colour turns to light blue. 6. Record the volume of titrant used in mls. 2.5.2 Calcium Hardness Test 2.5.2.1 Objective To determine calcium hardness of water samples 2.5.2.2 Sumary of Method Calcium and magnesium ions react with disodium ethylenediaminetetra acetate (EDTA) to form a complex solution. The end point of the reaction is detected by means of a calcium hardness indicator. It will change from reddish colour to royal blue, when the reaction is completed.
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2.5.2.3 Apparatus White porcelain casserole, measuring cylinder, burette 2.5.2.4 Reagent EDTA N/50 solution, ammonium buffer soltuion, BDH calcium hardness indicator tablet
(a)
(b)
(c)
Figure 2.8: (a) white porcelain casserole (b) BDH total hardness indicator tablet (c) BDH calcium hardness indicator 2.5.2.5 Procedure 1. measure 100 ml of water sample in a white porcelain casserole. 2. Add 2 ml of ammonium buffer solution. 3. Add 1 BDH calcium hardness tablet indicator and break it to dissolve. 4. Titrate with N/50 EDTA solution until the reddish colour turns to royal blue. 5. Record the volume of titrant used in mls. 2.5.3 Total alkalinity Test 2.5.3.1 Objective To determine total alkalinity in water sample. 2.5.3.2 Summary of Method The alkalinity of water is detemined by titration with a standard solution of an acid to end point with pH value at 4.5. the end pointsare detected with 4.5 BDH indicator, but if the water highly coloured, indicators are not suitable and the potentiometric method is advisable.
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2.5.3.3 Apparatus White porcelain casserole, measuring cylinder, burette 2.5.3.4 Reagents N/50 standard sulphuric acid solution, BDH 4.5 indicator
Figure 2.9: BDH 4.5 indicator 2.5.3.5 Procedure 1. Measure 100 ml of water sample into white porcelain casserole. 2. Add 3 drops of BDH 4.5 indicator and the solution will turn to blue colour. 3. Titrate with N/50 sulphuric acid. The end point is reached when the blue colour turns to grey. Record the volume of titrant used in mls. 2.5.4 Test for Iron Content 2.5.4.1 Objective To determine the iron content in water. 2.5.4.2 Summary of Method Soluble iron is determined by colorimeter using TPTZ iron regeant as an indicator. 2.5.4.3 Apparatus colorimeter 2.5.4.4 Reagent TTPZ iron reagent
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2.5.4.5 Procedure 1. The demin water and water sample are poured into the different colorimeter bottle until reached the mark. 2. TPTZ iron reagent is added to both demin water and water sample. 3. Put the colorimeter bottle containing demin water into the colorimeter. 4. The program for iron testing is selected. 5. ZERO button is pressed. 6. Then replace the demin water bottle with the water sample bottle and then the reading is recoded by pressing the READ button. 2.5.5 Test for Copper Content 2.5.5.1 Objective To determine the copper content in water. 2.5.5.2 Summary of Method Soluble iron is determined by colorimeter using copper regeant as an indicator. 2.5.5.3 Apparatus Colorimeter with bottle 2.5.5.4 Reagent Copper reagent
(a)
(b)
(c)
Figure 2.10: (a) colorimeter (b) colorimeter bottles (c) iron/copper reagent
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2.5.5.5 Procedure 1. The demin water and water sample are poured into the different colorimeter bottle until reached the mark. 2. Copper reagent is added to both demin water and water sample. 3. Put the colorimeter bottle containing demin water into the colorimeter. 4. The program for copper testing is selected. 5. ZERO button is pressed. 6. Then replace the demin water bottle with the water sample bottle and then the reading is recoded by pressing the READ button. 2.6 Task Assigned 2.6.1 Replacement of Resins in Mixed Bed Unit Since the function of mixed bed unit is just as the same as the function of anions and cations, it also contains resins to do the removal of cations and anions. These resins have five years lifetime, hence the replacement will be done once in every five years. The difference for mixed bed unit is that both anions and cations will be removed in the same one unit. Each mixed bed units consist of three layers, which by the top layer is the inlet of demin water and caustic reagent. The main pipe where demin water and caustic reagent flow is divided into two sides with seven PVC pipes on each side. The PVC pipes will touch the wall of the vessel wall. There are small holes on each PVC pipes that will allow the flow of water in droplets. Acid dilution will flow through the middle part of the mixed bed unit. The structure of pipes inside the middle layer is just as the same as in top part. In order to avoid the resin to flow out with water, the PVC pipes are covered with sand paper. Finally, the bottom part looks like mushroom shape. This mushroom shaped layer is known as strainer where the water will flow out of mixed bed unit. The strainer functions to avoid flow of resin together with water.
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Figure 2.11: Mixed Bed Unit
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Table 2.0: Layer of Mixed Bed Unit Layer Top Parts Explanation Main pipe for the flow of water and caustic reagent Demin water and caustic reagent inlet Divided into two side: every side has seven PVC pipes The length of the pipe until the vessel wall
Small holes on the PVC pipes
Middle
Acid
dilution
reagent
flow into main pipe Acid dilution flow in Main pipe joins the PVC pipes
PVC pipes are covered with sand paper
Bottom Final layer mushroom strainer
Mushroom shaped layer as a strainer
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2.6.1.1 Types of Resins in Mixed Bed Unit Since mixed bed unit functions to remove the remaining cations and anions, there will be three layers of resins used which by the upper layer is anion resins, ambersep 200H, the lower layer is cation resins, ambersep 900CL and the middle layer for the inert resins, dowex monosphere 600BB/359 used to separate cation and anion resins. Table 2.1: Type of Resins in Mixed Bed Unit Resin Old Resin (after 5 years) (TOP) Anion Resin Ambersep 200H New Resin
(MIDDLE) Inert Resin Dowex Monosphere 600BB/359
(BOTTOM) Cation resin Ambersep 900CL
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2.6.1.2 Steps in Replacement of Resins in Mixed Bed Unit
Draining
Degasses Release
Acid Inject
Backwash
Caustic Rinse
Acid Rinse
Recyclation
Settling
Caustic Inject
Drain down
Refill 2
Air Mixing
Refill 1
Figure 2.12: Steps in Replacement of Resins The water is drained out first from the mixed bed unit through. And also the old resins are blown down through the main hole. Then the new resins are filled. To begin the using of new resins, the regeneration process must be done which initiated with the backwash process. The water is filled into the mixed bed unit to wash the resins. After backwash, the resins are allowed to settle. The caustic reagent is injected to clean the anion resins. After anion resins cleaning is done, the water will flow continuously to rinse the caustic reagent. Then carbon dioxide will be released. The cation resins need to be cleaned by using acid. Acid is injected and after the cleaning, water once again will flow to rinse it. After the acid is rinsed, the water will be drained. Air is blown down to allow the mixing of resins in their separated layers. Then water will be refilled into the mixed bed unit. Regeneration process is repeated to ensure that the resins are active and pH and conductivity of the water in mixed bed unit achieve the specific range.
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3.0 CONCLUSION Trough this program, I have found that industrial training is very good for undergraduate students to complete their courses study. It gives an opportunity for bachelors to practice and understand on what they have learnt in university as well as get to experience a working environment which they will meet during the training. The advantages of the industrial training, which I am exposing here are particularly for those who are taking Chemical Engineering involving in the electricity power generation. During the training, I can observe and see the real mechanism used to generate electricity. Besides, I could explore more about the industrial system which may be sometimes did not mention or missed during lecture in university. When doing the inspection, I can follow authorized technician and in certain jobs, I can take part to do the work. By doing this, I could increase my knowledge because of the full explanation from the technicians and then get better understanding about the process. Industrial training also shapes me to be a better leader and team member. During the training, sometimes, I faced difficult situation. In certain circumstances, those situations require a quick and best decision. Besides getting experiences whic can be used in future when facing the same problems, I am specifically training my mind and my body to act efficiently. The most important thing from industrial training is that I have met a lot of new people from different background and characteristics. Meeting with new people makes me gain knowledge and mix with them to understand each other to produce high quality results in working.
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Industrial Training Report

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Industrial Training Report 2013