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 Train-
ing 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 sup-
port to undergo my training at SJSI. Above all, I would like to express a lot of thank-
fulness to my entire companion for your kindness helping me in difficulty.

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 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 effi-
ciency 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 com-
pressed 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 ro-
tating 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 pres-
sures, which is high pressure and low pressure superheated steam. The resulting su-
perheated 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 con-
densed (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.

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 TABLE OF COTENTS

CHAPTER TOPIC PAGE

1 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

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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 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
2.3.3 Turbine 36
2.3.3.1 Turbine Rotor 37
2.3.3.2 Turbine Stator 41
2.3.4 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
2.3.5 Bearing 46

3 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

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 3.8 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

4 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 Trace out Line for Cooling Water System 102

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 4.6.2 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 5’s in Brief 109

5 CONCLUSION 111

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 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

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 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

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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

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 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