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.

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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

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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

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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.

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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.

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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

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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 Nessler’s 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

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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.


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-2-

naphtol-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

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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.


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

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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.


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


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.


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


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.


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.


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 Parts Explanation

Top

Demin water and caustic

reagent inlet

Main pipe for the flow of

water and caustic reagent

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 flow in

Acid dilution reagent

flow into main pipe

Main pipe joins the PVC

pipes

PVC pipes are covered

with sand paper

Bottom

Final layer mushroom

strainer

Mushroom shaped layer

as a strainer

2.6.1.1 Types of Resins in Mixed Bed Unit

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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)

New Resin

(TOP)

Anion Resin

Ambersep 200H

(MIDDLE)

Inert Resin

Dowex Monosphere

600BB/359

(BOTTOM)

Cation resin

Ambersep 900CL

2.6.1.2 Steps in Replacement of Resins in Mixed Bed Unit

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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.

3.0 CONCLUSION

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Draining

Backwash

Settling Caustic Inject

Caustic Rinse

Degasses Release

Acid Inject

Acid Rinse

Drain down

Air Mixing

Refill 1

Refill 2

Recyclation


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

Documents

largest power plant

environmental section

usage of power

combined cycle project

electrochlorintaion

electrochlorination

plant performance

industrial training