Student Industrial Internship Program

PRESENTATION OUTLINE

Presentationo To describe and share the works and tasks done during the industrial

training.

Industrial Training Program

At the end of the industrial internship, student should be able to:

1. Apply theoretical knowledge in industrial applications.

2. Acquire skills in communication, management and team-work.

3. Practice ethical and professional work culture.

4. Implement Health Safety and Environment (HSE) practices at workplace.

OBJECTIVES

PETRONAS Gas Berhad (PGB)

Managing Director / Chief Executive Officer

POD TOD CUF Head Office

CCSD

TFDD

FAD

HSE

HRM

Support ServicesSupport ServicesSupport Services

Host Company

CUF

“COGEN” Plant

Demineralized Water Plant

Cooling Tower Unit

Nitrogen Generation Plant

Centralised Utility Facilities, CUF

Steam

108 MW

480 t/h430 oC

52 bar

300 oC

23 bar

170 oC

5 bar

HPHP

IPIP

LPLP

Generator 36 MW36 MW36 MW36 MW

HRSG (Boiler)

120 t/hr

X 3 units

X 4units

Fuel Gas

Gaseous Nitrogen

9.5 bar, ambient temperature

Liquefied Nitrogen

- 196 oC

Atmospheric Air NGU

Raw Water Demin Plant COGEN Plant

Customers

8700Nm3/hr

500 m3/hr

Silica = < 20ppb

Conductivity = < 0.2 µS/cm

• Water Chemistry• - Demin Plant • - Cooling water• - Boiler Feed Water

• Internal Combustion Engine• - Gas turbine

• Heat Transfer applications• -Heat exchangers• - Boilers• -Cryogenics ( -170 oC)

What did I learn ??

• Separation Process• -Extraction of Nitrogen from Air• -Purification of Nitrogen Gas

– Distillation Column– Reboiler Condenser

• -Water purification in Demin Plant– Multimedia Filters– Reverse Osmosis– Ion Exchange

• -Pressure Swing Adsorption– Air Driers– Molecular Sieves

• Mechanical • - Pumps

– Types of pumps– NPSH (Net Positive Suction Head)– Cavitation of Pumps

• Compressors– Types of compressors– Compressors Surging ( Surge Line)– Compressor efficiency

• Thermodynamics• -Brayton Cycle• -Refrigeration Cycle• -Superheated and saturated Steam

• Control & Instrumentation• - Distributed Control System• - Flow Meters• - Logic Diagram• - P & ID• -Valves• - Controllers

• Electrical• - Power Generation• Electrical Distribution System

ACTIVITIES

• Gas Turbine inlet Air Filters Replacement

Plant Activities

• Spider-Web Cellulosics Cartridges

• Number of cartridge : 144

• Type of cartridge pair : cylindrical + cone

• Why Replace : Pressure Drop increases across the

filters which eventually effects the compressor efficiency

• Spider-Web Cellulosics Cartridges

• Number of cartridge : 144

• Type of cartridge pair : cylindrical + cone

• Why Replace : Pressure Drop increases across the

filters which eventually effects the compressor efficiency

• MRO chemical Cleaning

• After a certain period of continuous operation, the RO

membrane becomes fouled with dirt and other minerals deposited

on the RO membrane.

• Chemicals Used : Sodium Hydroxide, Hydrochloric Acid,

detergent,

• Continues Monitoring of Parameters such as PH , Temp , and

pressure during RO chemical Cleaning must be done.

• After a certain period of continuous operation, the RO

membrane becomes fouled with dirt and other minerals deposited

on the RO membrane.

• Chemicals Used : Sodium Hydroxide, Hydrochloric Acid,

detergent,

• Continues Monitoring of Parameters such as PH , Temp , and

pressure during RO chemical Cleaning must be done.

• MRO membrane Replacement.

•MRO profiling data shows high

conductivity .

•Membranes never been replaced since

commissioning

• Total of 168 membranes replaced.

• Performance of MRO monitored after

that.

• All membranes condition was checked to

select the membranes to be re-used for

other unit.

• Profiling data shows positive result after

replacement.

•MRO profiling data shows high

conductivity .

•Membranes never been replaced since

commissioning

• Total of 168 membranes replaced.

• Performance of MRO monitored after

that.

• All membranes condition was checked to

select the membranes to be re-used for

other unit.

• Profiling data shows positive result after

replacement.

• Fire Water System Isolation.

• The system is sized to deliver a maximum flow rate of only 1220 m3/h (at 10 kg/cm2g)• Why isolate : - Pump Overhaul

- Valves repairing• Pressure inside the pipelines should be reduced by draining the water out of the pipes.

• The system is sized to deliver a maximum flow rate of only 1220 m3/h (at 10 kg/cm2g)• Why isolate : - Pump Overhaul

- Valves repairing• Pressure inside the pipelines should be reduced by draining the water out of the pipes.

• Daily Plant performance monitoring.

• Monitor NGU plant Overall Equipment Effectiveness every day to ensure the best running mode is selected for maximum plant optimization. • Join daily morning meeting with all other departments .

• Monitor NGU plant Overall Equipment Effectiveness every day to ensure the best running mode is selected for maximum plant optimization. • Join daily morning meeting with all other departments .

Slit Density Index to monitor the amount of suspended solid in water

Slit Density Index to monitor the amount of suspended solid in water

Hydrometer used to check the acid and caustic concentration during regeneration

Hydrometer used to check the acid and caustic concentration during regeneration

Level of resin need to be monitored to ensure proper separation for Regen

Level of resin need to be monitored to ensure proper separation for Regen

Projects

Undergoing•NGU 2 Debottlenecking•Preparing NGU training module for Operators.

NGU 2 Recycle Compressor Trip

28th February 2011 at 09:19:46 pm

Objective: To investigate the cause of recycle air compressor trip.

Methodology: - • Root Cause Analysis• Brain Storming• Based on system logs/trending and interview

staff.

Sequence of event:

Date Time Description

2/28/2011 09:19:46 Recycle Air compressor Trip Alarm activated at panel. No alarm at local.

2/28/2011 09:30:09 Attempt to start Recycle Air Compressor but failed due to Emergency Stop alarm.

3/1/2011 10:30:00 Start Recycle compressor but failed due to the “Emergency stop” alarm still appear at local panel. Can’t reset. Electrical checked at sub 4, no alarm appeared and compressor in healthy condition. Contacted

system Eng to check and rectify. (Reference : SS Log Sheet)

3/2/2011 00:24:00 Reduced inlet pressure recycle compressor to 3.6 bar, alarm still not clear.

(Reference: SS Log Sheet)

3/2/2011 09:15:00 Managed to clear trip alarm for NGU-2 recycle compressor. Started the recycle compressor.

(Reference: SS Log Sheet)

Recycle Air Compressor Trip

Inlet Air Pressure

Outlet Air Pressure High

Air Temp (Discharge &

Inlet)

High Low

Motor OverloadLube Oil

(Pressure/ Temp)

Emergency Stop Push Button

Button Pushed By Someone

Faulty Push Button

Not Available Unhealthy Relay

Loose Connection

Cable/ Wiring Problem

No alarm at Sub 4 (Checked by Electrical)

Indicates that the possible cause is checked and proved not true.

Inlet Pressure Control Valve

Recycle Valve. Opening Depends on Outlet pressure and Flow

Suspected reason that can cause Rec Comp to stop

Emergency Stop Push Button

Serv

ice

Dia

gram

for L

ocal

Pan

el )

• All process values were checked from the trending. No change in process values observed before recycle compressor trip. No warning alarm was activated before trip alarm.

• From the interlock alarm list, there were only two alarms on the list for recycle air compressor.

Alarms

Tag no: Service Location Detector Action

1B80-TRP Recycle Comp.Trip MMI Local Panel Switch(On at trip)

1B80-ALM Recycle Comp.Alarm MMI Local Panel Switch (On at alarm)

Recommendations:

• Loop Test for Push Button• Check the healthiness of the Relay(Recommended to be done during shutdown)• Reconfirm alarm list for recycle compressor.

• INSTRUMENT AIR COMPRESSOR TRIP ON 1ST March 2011 at 3.34pm

Objective: • To investigate the cause of Instrument Air Compressor trip.Methodology:• Panel interview• 5 whysAbstract : • Instrument air compressor tripped on 1st March 2011. 2 alarms were activated.• “Delivery Pressure High High”• “Interstage Pressure High High”• It has been reported that the trip had happen earlier also in the month of February

due to the same reason “Interstage Pressure High High” .• In both scenarios, the transmitter reading doesn’t shows that it has crossed the

limits but the alarm shows that the pressure is “High High”

• Observe several other trips which shows the same alarm.

• Inform Control and Instrument engineer

Action Taken

Mix Bed Exchanger A abnormal throughput

Root cause analysis

Regeneration

Action Taken

Way Forward

- Send resins for analysis to check Resin performance ( exchange capacity etc)

- Keep close monitoring on concentration of acid and caustic used for regeneration ( Hydrometer)

- Do feasibility study on this case and try to apply to other mix beds too (if resin analysis shows positive result)

Problem Statement :

Level of Liquid Nitrogen in storage tanks decreasing rapidly.

Objectives :

-To define possible causes of Lin Loss at NGU plant-To improve plant optimization and equipment efficiency

LIN Loss at Storage Tanks

Vacuum Space

Expanded Perlite

Liquid Nitrogen

Valtek Valve

Vaporizer

PBC

Filling Filling

Valtek Valve

Vaporizer

PBC

Possible causes :

• Valtek Valve Passing • Insufficient Vacuum Pressure• Perlite Insulation Slippage

Estimated Loss

For one tank / year

• Vacuum Pressure of the thermal insulation was more than the required pressure.

• Very thick layer of icing at the vent line.

Findings

Way Forward

• To perform vacuuming for all the storage tanks

• To service the valtek valve

• Problem Statement - No exact information available about how much volume of

chemical is consumed or added to the tank.

- Only the level of liquid inside the tank is available

- normal Лr2L formula cant be use since the tank is Horizontal not vertical .

Template for total chemical Consumed during Regen and Total amount of chemical Top-uped

300mm

300mm

NGU Debottlenecking

Debottlenecking is to improve and existing facility’s capacity and profitability.

Nitrogen Recovery : Gas and liquid Nitrogen in Product Feed air flow to Cold Box + Recycled air

Current Nitrogen Recovery: 6000___ 11350+4500 : 37 %

7000 Nm3/hr Target

• Identify the bottlenecks• Gather all equipment datasheets and current running mode• Check DCS setting , Interlocks, and Transmitter ranges• Test run

• Boiler Shutdown.• Gas Turbine Shutdown• Demin Plant Shutdown• ASU Shutdown• Isolation List• Blind List

Unit Shutdown

Importance of good planning Importance of leadership skills Importance of safety Importance of communication with contractors Importance of punctuality

Inside a Mix Bed ExchangerInside a Mix Bed Exchanger Siphoning method used to unload media Siphoning method used to unload media

• Permit to work• Safety tips• Process Safety Management• Job Safety Analysis• Process Hazard Analysis• Pre-Activity Safety Review• Safety Observation

Health, Safety and Environment

• Gas Turbine training by Senior Panel • CCMS and control system training by TP• Vendor Presentations• DCS (Distributed Control System) upgrading.

Training ,Classes etc

• Overall Equipment Effectiveness for NGUQuality Production _______________ X 100 Adjusted Capacity

• Throughput for Mix Bed Exchanger and Condensate Polisher.

Data Compilation

Improving the Overall Equipment Effectiveness by just 1% can lead to a disproportionate change in throughput and consequent reduction in unit cost of the product Previously, was checked monthly, Now, updated daily and immediate action is taken to overcome any gap.

Volume of demineralized water produced after regeneration until the resins are exhausted. To see regen efficiency To monitor mix bed and CP performance

• Monthly Operation Report Alarm Management NGU OEE Power OEE Plant Highlights

• Co-generation UnitHeat RateHeat Rate = NG Consumption (NM3) X GCV(MJ/NM3) X 1000(KJ/MJ)

Unit Power Generated(kwh)

= 12079 kj/kwh

GT Efficiency= Unit Power Generated (Mwh) X 3600 (Mj/Mwh) NG Consumption (KG) X GCV(MJ/NM3) / Density (kg/NM3)

X 100 = 30.2 %

Generation Index

“Standard Reference Fuel” (SRF) is used to place fuels withdifferent calorific values on a common basis

40.5 GJ = 38.38 MMBTU = 9.67 GkCal = 1 TSRFElectricity: 3.5 MWh Electricity = 1 TSRFSRF Steam (pressure level): Tonnes to Tonnes SRF

Deliveredy Electricit & Steam Total

y Electricit & Steam generate toConsumed Fuel TotalIndex Generation

• MRO performance monitoring Water Recovery Salt Rejection Feed Pressure Pressure Drop Across the different stages. MRO Profiling ( PH and Conductivity of product from each vessel )

• Overall Demin, NGU, Cooling Water, Instrument Air Plant Performance Monitoring Template

LESSON LEARNT

• The university should make a system that is not totally marks oriented, but knowledge oriented.o Plant visit.o Make good use of Lab sessions

• The internship period should be 6 months

RECOMMENDATION

UTP

CUF

• To have a training schedule for trainees

• To allow trainees to be part of organizing committee of events

• An excellent practice for students to gain experience and knowledge about real-life working environment.

• An improvement platform of personal skills such as management skills, social skills and communication skills.

CONCLUSION

• I would like to acknowledge my appreciation to Dr Azmi for coming here.

• Special acknowledgement to Mr. Jayavishnu (Plant Supervisor) for his support and guidance and to all CUF staff for their co-operation, openness and hospitality .

Q & A

Q & A