The QUZ cooler at unit 1 was suspected to be leaking. Tested with air pressure. Where air was supplied to the inlet of steam and the outlet was blanked. If there was a leak, bubbles can be seen at the coolant line flow indicator. But there was no bubbles. Therefore, the cooler is not leaking.
Replaced LFO drip tank pump stator.
Repaired GGH lower cleaning lance nozzle.
Closed all manholes at unit 1 FGD.
Serviced ESP gearbox. The gearbox internal compartment was disassembled and the inner surface of the gearbox was painted with protective paint. Besides that, all the bearing and gearbox oil ring was replaced.
Thursday, July 1, 2010
week no.11
Due to fly ash stuck inside the blow tank, the bottom semi sphere of the blow tank was opened to be cleaned.
Changed volume booster at unit 1 Induced Draft (ID) fan.
Cleaned unit 1 FD fan and PA fan.
Did preventive maintenance at unit 2 GGH. Check GGH guide bearing oil level. The oil used is Mobilgear 636.
Applied grease to Force Draft (FD) fan inlet guide vane rollers.
Changed volume booster at unit 1 Induced Draft (ID) fan.
Cleaned unit 1 FD fan and PA fan.
Did preventive maintenance at unit 2 GGH. Check GGH guide bearing oil level. The oil used is Mobilgear 636.
Applied grease to Force Draft (FD) fan inlet guide vane rollers.
week no.10
The defect was at unit 1 boiler circulation pump (BCP), non-return valve. There was a leak at the valve. Therefore, the gland packing was changed.
Changed gland packing at superheated steam drain pot level switch isolation valve.
Changed gland packing at atomizing steam control valve.
Cleaned all 16 LFO burner gun nozzle head at unit 1 boiler.
Lapping process was done on the boiler drum gauge glass due to steam leaking.
Changed gland packing at superheated steam drain pot level switch isolation valve.
Changed gland packing at atomizing steam control valve.
Cleaned all 16 LFO burner gun nozzle head at unit 1 boiler.
Lapping process was done on the boiler drum gauge glass due to steam leaking.
week no.8 & 9
Joined the On Job Training (OJT) & Simulator section. The training was held for two weeks. The content of the syllabus are as follow:
• Water and fire fighting system
• Light Fuel Oil (LFO)
• Cooling water system
• Close circuit cooling water (CCCW)
• Condensate system
• Feed water system
• Boiler
- Boiler house
- Steam by pass system
- Combustion air
- Flue gas
- Auxiliary steam
- Soot blowing
- Coal and mills
• Turbine
- Turbine overview
- Lubricating and jacking oil
- Gland steam
- Turbine drain
- Control fluid
- Condenser vacuum
• Generator
- Generator overview
- Seal oil system
- Hydrogen cooling
- Stator cooling water
- Excitation system
- Electrical output
• Water and fire fighting system
• Light Fuel Oil (LFO)
• Cooling water system
• Close circuit cooling water (CCCW)
• Condensate system
• Feed water system
• Boiler
- Boiler house
- Steam by pass system
- Combustion air
- Flue gas
- Auxiliary steam
- Soot blowing
- Coal and mills
• Turbine
- Turbine overview
- Lubricating and jacking oil
- Gland steam
- Turbine drain
- Control fluid
- Condenser vacuum
• Generator
- Generator overview
- Seal oil system
- Hydrogen cooling
- Stator cooling water
- Excitation system
- Electrical output
week no.7
Replaced Light Fuel Oil (LFO) pump bearing. After assemblingthe new bearing, the two coupling halves were precisely aligned.
Attended program Sisih Perdana 2, which was held at TNBJ 1 building.
Disassembled soot blower gearbox at unit 1 long retractable soot blower. Before disassembled soot blower gearbox, the steam pipe to the soot blower was blanked. The gearbox was then brought back to workshop for servicing.
Serviced auto drain valve at unit 2 Electrostatic Precipitator (ESP) buffer tank.
Top up compressor oil at instrument air house.
Attended program Sisih Perdana 2, which was held at TNBJ 1 building.
Disassembled soot blower gearbox at unit 1 long retractable soot blower. Before disassembled soot blower gearbox, the steam pipe to the soot blower was blanked. The gearbox was then brought back to workshop for servicing.
Serviced auto drain valve at unit 2 Electrostatic Precipitator (ESP) buffer tank.
Top up compressor oil at instrument air house.
week no.6
Collected sample oil from ID fan, FD fan, FGD fan, and PA fan. The sample oil was collected from drain valve at each of the fan. These sample oil will be sent to R&E section and they will test the oil viscosity.
Online sealing repair at unit 1 steam pipe. The work was done by In-Situ contractors, where clamp were used to seal the leakage.
A soot blower lance tube was stuck in the furnace while the motor and blower carriage retracted back to its original position. It was due to broken bolt, which was connecting lance tube and blower carriage. The lance tube was then pulled out using chain block.
Top up oil at air heater guide bearing.
Went to inspect air heater soot blower. It was suspected not functioning well.
Tightened packing nut at all unit 3 soot blower. Besides that, lubrication spray was sprayed at the soot blower chain.
Online sealing repair at unit 1 steam pipe. The work was done by In-Situ contractors, where clamp were used to seal the leakage.
A soot blower lance tube was stuck in the furnace while the motor and blower carriage retracted back to its original position. It was due to broken bolt, which was connecting lance tube and blower carriage. The lance tube was then pulled out using chain block.
Top up oil at air heater guide bearing.
Went to inspect air heater soot blower. It was suspected not functioning well.
Tightened packing nut at all unit 3 soot blower. Besides that, lubrication spray was sprayed at the soot blower chain.
week no.5
The manufacturer of the fly ash compressor, Ingersoll Rand came back to reattend the defective compressor. The repaired AN of the compressor was installed back. After the installation the compressor was tested by Research &Engineering (R&E) section, and it was functioning well.
Cleaned the flame scanner cooling air fan filter at unit 1.
Did regular maintenance at service air compressor in unit 1 instrument air house. The regular maintenance is done every 8000 hours of the compressor operation.
Unit 1 burner gun seal air fan bearing replacement. The bearing housing was first cleaned, before new bearing was installed. The defected bearing was identified by R&E section, where they use sound frequency measurement to detect it.
Did alignment at burner gun seal air fan. The equipment used to do the alignment is diel gauge and telescopic gauge. Shim is placed under the motor to align it with the shaft. The maximum displacement between shaft and motor must be less than 0.1mm.
Cleaned the flame scanner cooling air fan filter at unit 1.
Did regular maintenance at service air compressor in unit 1 instrument air house. The regular maintenance is done every 8000 hours of the compressor operation.
Unit 1 burner gun seal air fan bearing replacement. The bearing housing was first cleaned, before new bearing was installed. The defected bearing was identified by R&E section, where they use sound frequency measurement to detect it.
Did alignment at burner gun seal air fan. The equipment used to do the alignment is diel gauge and telescopic gauge. Shim is placed under the motor to align it with the shaft. The maximum displacement between shaft and motor must be less than 0.1mm.
week no.4
Pulverized coal (PC) leaking at flange located after PC cooling air damper. Therefore, the bolt and nut were tighten to seal the connection properly.
Changed lube oil filter at unit 3 air heater guide bearing.
Safety valve regular maintenance by outside contructers at boiler drum, reheater, and superheater. The purpose of safety valve is to release the system’s pressure in case of axcessive pressure.
Did inspection at all unit 3 valves to check for leakage. A portable temperature gun was used to do the inspection.
Disassembled blower carriage and puppet valve at unit 2 long retractable soot blower. The blower carriage and puppet valve was then brought back to workshop for servicing.
Changed lube oil filter at unit 3 air heater guide bearing.
Safety valve regular maintenance by outside contructers at boiler drum, reheater, and superheater. The purpose of safety valve is to release the system’s pressure in case of axcessive pressure.
Did inspection at all unit 3 valves to check for leakage. A portable temperature gun was used to do the inspection.
Disassembled blower carriage and puppet valve at unit 2 long retractable soot blower. The blower carriage and puppet valve was then brought back to workshop for servicing.
week no.3
Replaced leaking host at unit 3 hydraulic oil unit for HP bypass V.
Preventive maintenance (PM) at unit 1 long retractable soot blower. During the preventive maintenance, all the soot blowers were checked for steam leakage. Besides that, the broken center support cam was replaced.
The defect was at unit 3, QUZ boiler steam sampling system. One of the cooler was leaking. Therefore, the cooler was replaced with new cooler.
Learned about boiler drum and steam circulation path in boiler. The function of boiler drum is to separate the steam generated in the furnace walls tubes from water.
Preventive maintenance (PM) at unit 1 long retractable soot blower. During the preventive maintenance, all the soot blowers were checked for steam leakage. Besides that, the broken center support cam was replaced.
The defect was at unit 3, QUZ boiler steam sampling system. One of the cooler was leaking. Therefore, the cooler was replaced with new cooler.
Learned about boiler drum and steam circulation path in boiler. The function of boiler drum is to separate the steam generated in the furnace walls tubes from water.
week no.2
Went to visit unit 1 gas – gas heat exchanger (GGH) with boiler maintenance section foreman, Mr. Superman. The GGH of out of service due to damaged GGH guide bearing.
Changed coolant and coolant filter for air compressor of fly ash system.
Attended a presentation by IHI Corporation on IHI Ultra Super Critical (USC) Boiler. The content of the presentation includes the description of USC boiler, technical advantage of USC boiler, and comparison of USC boiler and natural circulation boiler.
Refilled fuel for portable compressor. A manual pump was used to pump out fuel from drum to the compressor.
Serviced auto drain valve at Instrument Air House, wet air receiver tank.
Changed coolant and coolant filter for air compressor of fly ash system.
Attended a presentation by IHI Corporation on IHI Ultra Super Critical (USC) Boiler. The content of the presentation includes the description of USC boiler, technical advantage of USC boiler, and comparison of USC boiler and natural circulation boiler.
Refilled fuel for portable compressor. A manual pump was used to pump out fuel from drum to the compressor.
Serviced auto drain valve at Instrument Air House, wet air receiver tank.
week no.1
First day report in at TNB Janamanjung
A brief introduction about the power plant by Mr. Nurul Akla
Attend to safety induction which conducted by Mr.Wan Azhanizam. After the safety induction safety helmet and hear muff has been given.
collected touch n go entry pass from safety manager Mr. Salleh
Visit to plant site with Mr. Nurul Akla
Briefing on general administrative information and ISO familiarisation
Was introduced to boiler maintenance section senior engineer
I was assigned at boiler maintenance section
Went to inspect pulverized coal (PC) pipe leakage
A repair was carried out on air compressor no. 13 at Fly Ash Compressor House. The AN of the compressor was dismantled and sent to manufacturer for repair.
The defect was on Induced Draft (ID) fan, one of the inlet guide vane roller nearly came out of the crown. Force was used to push it back inside.
Replaced punctured compressor hose used to connect portable compressor and outlet of air compressor no. 14 at fly ash compressor house.
A brief introduction about the power plant by Mr. Nurul Akla
Attend to safety induction which conducted by Mr.Wan Azhanizam. After the safety induction safety helmet and hear muff has been given.
collected touch n go entry pass from safety manager Mr. Salleh
Visit to plant site with Mr. Nurul Akla
Briefing on general administrative information and ISO familiarisation
Was introduced to boiler maintenance section senior engineer
I was assigned at boiler maintenance section
Went to inspect pulverized coal (PC) pipe leakage
A repair was carried out on air compressor no. 13 at Fly Ash Compressor House. The AN of the compressor was dismantled and sent to manufacturer for repair.
The defect was on Induced Draft (ID) fan, one of the inlet guide vane roller nearly came out of the crown. Force was used to push it back inside.
Replaced punctured compressor hose used to connect portable compressor and outlet of air compressor no. 14 at fly ash compressor house.
Tuesday, April 20, 2010
Sultan Azlan Shah Power Station (TNB Janamanjung) Overview
TNB Janamanjung Sdn Bhd was incorporated in august 1996 to spearhead the design, development and management of the station which was to be coal-fired. This plan has introduced to reduce dependence on natural gas as fuel source for power generation. The power plant is design to operate within the world bank emission limits aimed at minimizing power plant impact on the environment.
The power plant is located on a 325 hectare wholly man made island off the lekir coast in manjung perak. The plant delivers 2100 MW of net power from 3 × 700 MW generators. Sultan Azlan Shah Power Station (TNB Janamanjung) comprises three identical power generation units with drum type boilers, 700MW axial flow turbines, and hydrogen and water cooled generators, these are supported by specialized mechanical and electrical equipment to ensure high availability and reliability.
The plant utilises imported coals as the main fuel with light fuel oil (LFO) for lighting-up, or when operating at low loads. Both bituminous and sub-bituminous coals are used, with the proprietary Flue Gas Desulphurisation being employed to ensure low SO2 emissions. The water used in the cooling and FGD processes is drawn from the sea.
The output of the plant is optimised for grid system flexibility, with the ability to participate in system frequency regulation, as is required under stipulations of the Malaysian Grid Code, and also in compliance with approved international standards.
The power plant is located on a 325 hectare wholly man made island off the lekir coast in manjung perak. The plant delivers 2100 MW of net power from 3 × 700 MW generators. Sultan Azlan Shah Power Station (TNB Janamanjung) comprises three identical power generation units with drum type boilers, 700MW axial flow turbines, and hydrogen and water cooled generators, these are supported by specialized mechanical and electrical equipment to ensure high availability and reliability.
The plant utilises imported coals as the main fuel with light fuel oil (LFO) for lighting-up, or when operating at low loads. Both bituminous and sub-bituminous coals are used, with the proprietary Flue Gas Desulphurisation being employed to ensure low SO2 emissions. The water used in the cooling and FGD processes is drawn from the sea.
The output of the plant is optimised for grid system flexibility, with the ability to participate in system frequency regulation, as is required under stipulations of the Malaysian Grid Code, and also in compliance with approved international standards.
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