Chapter 1: Organization Background

1.1 General

With a booming economy, aided by the government‟s push for Malaysia to achieve fully

industrialised status by the year 2020, ordinary Malaysians and the business community are

discovering the price for growth and success. Presently, the total demand for electricity is

approximately 10, 000 Megawatts and it is likely to rise at a rate of 10% until the year 2020. A

nationwide blackout in September 1992 resulted in a loss of millions of ringgit to Malaysian

businesses. Shortly after the 1992 blackout, the Malaysian government ordered the national

power company, known locally as Tenaga Nasional Berhad (TNB) to revive the old plants and

upgrade the existing plants. The government began issuing licenses to Independent Power

Producers (IPP). Altogether, it has awarded licenses to five IPPs – three of these being the base-

load plants (running 24 hours) and two being peaking plants (running for 8 hours a day or “as

and when” TNB requires it).

1.2 Company Profile

In racing to meet the country‟s needs for more power, Port Dickson Power Berhad (PDP)

as a fast track Independent Power Producer (IPP) generated its first charge of electricity to

Tenaga Nasional Berhad (TNB) on the 2nd of September 1994. Port Dickson Power Berhad is a

joint venture between Sime Darby Berhad (40%), Malaysian Resources Corporation Berhad

(30%), Hypergigantic Sendirian Berhad (20%) and Tenaga Nasional Berhad (10%). The power

plant is operating according to the „open cycle system‟ and will supply power to Tenaga

Nasional Berhad on a peaking basis. At the request of National Load Dispatch Center,

Figure 1. 1: The Power Station Aerial View

Port Dickson Power Berhad has incorporated the Automatic Governor Control. This

allows the National Load Dispatch Center in Kuala Lumpur to directly control our station‟s

output according to varying load demands. The system consist of a mainframe with input

parameters e.g. load, frequency etc., and its output, to raise or lower megawatt, is sent to all

stations that are connected to it. The RM 700 Million power plant, located on a 67-acre site in

Tanjung Gemuk is equipped 4 x 110 Megawatt General electric (USA) gas turbines.

The power plant utilizes natural gas supplied by Petronas Gas Sdn Bhd as its primary

fuel. It is also able to use diesel light distillate piped from the Shell Refinery at Port Dickson as a

back up fuel. In the event of loss of supply from TNB, a standby Diesel Engine Powered

Generator of 2.6 MW capacity can provide the needs of power plant‟s internal requirements. In

fact, this generator can be used to start up the 4 machines sequentially to restore power to the

National Grid. This was done during the national blackout in 1995. Below are the equipment

data summaries regarding the gas turbine and generators used at Port Dickson Power Berhad: -

General Design Data of Gas Turbine:

Gas Turbine Model Series: - MS9001

Design Memo Number: - GR0293

Model List Number: - 9A1PEA68-1, -2, -3, -4

Gas Turbine Application: - Generator Drive

Cycle: - Simple

Shaft Rotation: - Counterclockwise

Turbine Shaft Speed: - 3000r.p.m

Control System: - SPEEDTRONIC Mark V solid-state electronic control sys.

Protection Devices (Basic Types):

o Over Speed Trip

o Over Temperature Trip

o Vibration Sensors

o Flame Detection

General Design Data of Generator

Generator Model: - 9H2

Serial Number: - 335X962,63,64,65

Shaft Rotation: - Counterclockwise

Shaft Speed: - 3000r.p.m

Cooling Medium: - Hydrogen

Pole: - 2

Phase: - 3

Load Connection: - „Wye‟ connection

Frequency: - 50Hz

Port Dickson Power Berhad has planned to convert the currently operating gas turbines from

the “Open Cycle System” to the „Combine Cycle System‟. This will include the installation of

steam boilers but currently the plan has been put on hold. Port Dickson power Berhad is also

exploring opportunities to venture out in the power industry at Australia.

1.3 Plant Management Overview

The Operation and Maintenance of the power station is contracted by Port Dickson

Power Berhad to Janaurus Berhad under the Operation and Maintenance Agreement. Port

Dickson Power Berhad is represented by an Executive Director, a Financial Controller, a

Commercial Manager and a Project Engineer supported by a group of finance accounting and

clerical staff. The Operation and Maintenance Organization is functionally based with Operation

and Maintenance Departments. The operation technicians work on a 3-shift rotation, 24 hours

per day, throughout the year whereby each shift will be under the supervision of a Shift Charge

Engineers. The maintenance workers work on a normal 5 days per week.

Janaurus Berhad manages two functional departments, the operation and maintenance of

the power station and assists Port Dickson Power Berhad in performing its role as requested. The

Operation Department‟s function is to ensure the safe and efficient operation of the plant at the

output required by Tenaga Nasional Berhad from time to time and the requirements of the

Operation and Maintenance. On behalf of Port Dickson Power Berhad, Janaurus Berhad makes

declarations to the National Load Dispatch Centre for plant output and availability and any

constraints in accordance with Port Dickson Power Berhad instructions and prevailing plant

conditions. The Operation Department monitors plant parameters and conditions and report to

the Maintenance Department of any defects or plant abnormalities, which they themselves

cannot correct within their resources. Operations ensure that the necessary materials and

services, which they require to operate the plant, are procured.

The Maintenance Department‟s function is to keep the plant, station infrastructure, tools

and equipment in good condition thus maintaining the high degree of reliability, availability,

efficiency required by the Operation and Maintenance Agreement and best industry practice. The

Maintenance staffs are divided into skill based function groups each with their respective Head

of Department. The four sections that comprise the maintenance department are the mechanical

section, electrical department, control & instrumentation (C & I) section and the planning

section. The maintenance staff is responsible for providing preventive and corrective

maintenance. The annual inspections and any large-scale corrective maintenance, which is

outside the capacity of the maintenance staff, are contracted out to contractors.

The Maintenance Department is also responsible for budgeting, planning and procuring

all the contracts materials and services required to perform its duties. The Department is also

responsible for procuring and maintaining a stock of plant spares and materials sufficient for the

needs of the plant to maintain its high reliability, availability and efficiency but consistent with

the budget approved by Port Dickson Power Berhad.The Maintenance Department also provides

other services necessary for the other departments to efficiently carry out their duties. These

services include maintenance of stores and maintenance controllers, computer systems,

documentation systems and control, technical and specialist services (either in-house or

contracted in) and any other services required. This department is also responsible for assisting

Port Dickson Power Berhad in their dealings with their contracts and statutory duties.

Technician Assistant

a. Assisting Technicians for daily activities and outage work.

b. Eracting and dismantling scaffolding and platforms.

c. Observing all procedures and safety rules and being responsible for their own actions.

d. Responding to call outs when requested.

e. Driving the station pickup truck or forklift as required.

f. Undertaking other duties as assigned from time to time by the Management.

C & I Technician

a. Servicing, repair and trouble shooting of pressure temperature, flow indicators,

transducers, process controllers, programmable logic controllers, P, PI, PID controllers,

analogue and digital input output systems and converters, distributed control systems and

all other instrumentations system related to the plant.

b. Use of testing and diagnostic tools.

c. Collection and utilization of spares as required.

d. Reporting and documenting of work carried out.

e. Use of technical manuals and drawings as necessary.

f. Controlling the activities of Assistant Technicians assigned to them.

g. Observing all procedures and safety rules and being responsible for the safety of their

own actions and of those working under their control.

h. Responding to call out when requested.

i. Undertaking other duties as assigned from time to time by the Management.

Mechanical Technician

a. Under instruction from the Head of Section, dismantling, servicing, and reassembling

mechanical plant as directed. These include gas turbine compressor, combustion and

turbine systems, lubricating systems, starting systems, inlet and exhaust systems,

auxiliary cooling systems, fuel handling systems, fire fighting systems, pumps, valves

and fittings.

b. Welding, cutting, grinding, fitting, use of machine tools. Collection and utilization of

spares as required. Reporting on work carried out. Use of technical manuals and drawings

as necessary. Controlling the activities of Assistant Technicians assigned to them.

Observing all procedures and safety rules and being responsible for the safety of their

own actions and of those working under their control.

c. Responding to call outs when requested.

d. Undertaking other duties as assigned from time to time by the Management.

Shift Charge Engineer

1. The Shift Charge Engineer is responsible for the following:

a. During his shift the SCE together with the Operation Technicians will be in-charge of

the whole plant operation. After normal working hours only the SCE and Operation

Technicians will be manning the whole plant.

b. The SCE is responsible for the starting up and the shutting down of the gas turbines

and auxiliary equipment under the instruction from NLDC. He will ensure that the

machines are operated reliably and safely by controlling and maintaining all

parameters to be within specified limits.

c. Ensuring that the dispatching requirements of Tenaga Nasional (Grid System

Operated) are fully satisfied at all times as per PPA.

d. Making plant safe for the maintenance work to be carried out by enforcing the proper

isolation and normalization procedures.

e. In addition to the daily operation of the plant, the Shift Charge Engineer is

responsible for carrying out routine checks and tests to ensure safe and reliable

operation of the plant.

f. He is responsible for monitoring the performance of the machines and raises any

abnormalities in the operating parameters to the management team at the monitoring

meeting. He is trained to recognize fault that may require immediate action.

2. To carry out other works as assigned from time to time by Management.

1.4 Gas Turbine Introduction

The turbine unit is composed of an axial-flow compressor, multi-stage turbine, support

systems, combustion system components and a starting device. Both compressor and turbine are

directly connected with an in-line, single-shaft rotor supported by pressure-lubricated bearings.

The inlet end of the rotor shaft is coupled to an accessory gear that has integral shafts.

Figure 1. 2: Gas Turbine Unit

Turbine

Section

Combustion

Section

Compressor

Section

Accessory

Compartment

Exhaust

Compartme

nt

1.4.1 Compressor Section

This axial-flow compressor section consists of the compressor rotor and the enclosing

casing. The Inlet Guide Vanes, 17 stages of rotor and stator blades, and the Exit Guide Vanes are

inside the compressor casing. The air is confined to the spaces between the rotor and the stator

blades whereby it is compressed in stages by a series of alternate rotor and stationary air fold-

shaped blades. The rotor blades supply the force needed to compress the air in each stage and the

stator blades guide the air so that it enters the following rotor stage at the proper angle. The

compresses air exits through the compressor discharge casing to the combustion chambers. A

large portion of the turbine‟s work is absorbed by the compressor (approximately 1/3) because

compressed air plays a very important role during the operation of the machine. It has extensive

usage such as: -

Cooling air for turbine internal parts

Sealing air for turbine bearings No.1, No.2 and No.3

Combustion air

Control air for air operated valves

For pulsation protection of the turbine

Inlet air pressure at the compressor = ambient pressure

The outlet air pressure during Full Speed No Load = 6 Bar

Inlet temperature at the compressor = ambient temperature

The outlet temperature of compressor at Full Speed No Load = 320C

1.4.2 Combustion Section

Combustion system used here is a reverse flow type with 14 annular combustion cans

around the periphery of the compressor discharge casing (Figure 1.5). This system also includes

fuel nozzles, spark plug, ignition system, flame detectors and crossfire tubes. Hot gases

generated from burning of fuel in the combustion chambers are used to drive the turbine.

a. Spark Plugs

Combustion is initiated by means of the discharge from 2 high voltage retractable-

electrode spark plug located at combustion canisters number 13 and 14. These spark

plugs receive their energy from Ignition Transformer. Either one or both of the spark

plugs ignites the gas in the chamber while crossfire tubes ignite the remaining chambers.

As the speed increases chamber pressure causes the spark plugs to retract and the

electrodes are removed from the combustion zone.

b. Ultraviolet Flame Detectors

During the starting sequence, it is essential that an indication of the presence or absence

of flame be transmitted to the control system. These ultraviolet flame detectors are

located combustion cans number 4, 5, 10 and 11. These sensors contain gas-filled

detector. These gases within the detector are sensitive to presence of ultraviolet radiation

emitted by hydrocarbon flame. If flame is present then the ionization of gas in the

detector allows for conduction in the circuit, which gives an output defining „flame‟.

Conversely, the absence of flame will generate output defining „no flame‟.

c. Fuel Nozzles

Each combustion chamber is equipped with a fuel nozzle that emits a metered amount of

fuel into the combustion liner. Gaseous fuel is admitted directly into each chamber but

whenever liquid fuel is used, it is atomized by using high pressurize air to produce a more

complete combustion.

d. Crossfire Tubes

Crossfire tubes interconnect all 14 combustion cans. These tubes allow flame from fired

chambers to propagate to the unfired chambers.

1.4.3 Turbine Section

The 3-stage turbine section is the area whereby energy from high temperature pressurized

gas produced by the compressor and combustion sections is converted into mechanical energy. It

consists of 2 wheel shafts, first, second and third – stage turbine wheel with buckets and 2

turbine spacers.

a. Buckets

The turbine buckets increases in size from the first to the third stage. Due to the pressure

reduction resulting from energy conversion in each stage an increased annulus area is

required to accommodate gas flow. The first and second stage buckets have their

internally air-cooled system to accommodate for the high temperature of the hot gases.

Turbine rotor must be cooled to obtain reasonable operating temperatures and to ensure

longer life span for the turbine. Cooling is achieved by a positive flow of cool air radially

outward through a space between the turbine wheel with buckets and the stator in to the

main gas stream. This area is called the „Wheel space‟.

b. Turbine Stator

The turbine shell and the exhaust frame constitute the major portion of the MS9000 gas

turbine stator structure. There are 3 stages of nozzles, which direct the high velocity of

the hot expanded gas against the turbine buckets causing the turbine to rotate. These

nozzles are subjected to thermal stresses.

c. Shrouds

Unlike compressor blades, the turbine buckets do not run directly against the machine

surface of the casing but against annular curved segments called turbine shrouds. These

shrouds primary purpose is to provide a cylindrical surface for minimizing bucket tip

clearance leakage. Besides these, shrouds provide high thermal resistance between the

hot gases and the comparatively cooled shell.

1.4.4 Bearings

This gas turbine contains 3 main journal bearings to support the gas turbine rotor.

a. Bearing No.1: - Located at the bell mouth. Consists of loaded thrust, unloaded thrust and

one journal bearing.

b. Bearing No.2: - Located inside turbine compartment, cannot be seen and can withstand

high temperature. It is a journal bearing.

c. Bearing No.3: - Located at the turbine-end of the load compartment. It is a journal

bearing.

Figure 1. 3: The Frame 9E Gas Turbines That Are Used At Port Dickson Power Berhad

1.5 Generator Introduction

This hydrogen cooled turbine generator is completely enclosed for operation with

hydrogen gas as the cooling medium. The ventilation system is completely self-contained,

including gas-coolers and fans thus preventing the entrance of dirt and moisture. The separately

excited rotating field driven by turbine is supported by bearings located in the end shields

mounted on the generator frame. The generator is designed to operate continuously and includes

all the necessary systems for maintaining constant internal hydrogen pressure and purity, for

supplying cooling water and lubricating oil. Rotor fans located on each end of the unit provide

circulation of the hydrogen throughout the generator frame. The generator construction will

withstand all normal conditions of operation and 3-phase short circuits and their associated

suddenly applied loads without harm. The generator casing is designed to limit the destructive

effects of an instantaneous hydrogen detonation to the generator casing and enclosed parts. The

table below shows the advantages and the disadvantages of hydrogen-cooled generator:

Advantages Disadvantages

Reduce wind age losses Risk of explosion

Improve heat transfer coefficient Carbon Dioxide is needed for purging of hydrogen

gas during emergencies or maintenance work.

Improve thermal conductivity Sealing system is complicated and extra

accessories are needed

Eliminate risk of fire due to electrical failure Costly

The generator is comprised of the stator and the rotor and this two come in handy when it

comes to producing the desired output power. The rotor is fixed on the shaft and rotates

according to the shaft speed and the stator on the other hand is stationary. The rotor is mounted

with windings that produce magnetic flux if it is supplied with D.C current. The D.C current is

supplied to the rotor by the carbon brushes and the slip rings fixed on the rotor. By using the

carbon brushes, the wires that supply the D.C current do not get tangled up while the shaft is

running at full speed. The stator windings are used to cut the flux that is produced from the rotor

windings. These windings are assembled such a way that each winding is 1200 apart in order to

generate three-phase voltage. One end of each of the stator winding is connected to a common

ground where else the other end is connected to the bus bars that lead to the Generator Step-Up

Transformer. The end which has a common ground is installed with various protection relays

such as the ground faults rely and overload relay. These relays will protect the stator windings

and the generator on the whole from being exposed to damages caused by the high voltage

produced.

Figure 1. 4: The Magnetic Windings on the Rotor Are Supplied With D.C Current

Slip Rings

Carbon Brush

Chapter 2: Mechanical System

2.1 Atomizing Air and Purge Air System

When liquid fuel oil is sprayed into the turbine combustion chambers it forms large

droplets as it leaves the fuel nozzles. The droplets will not burn completely in the chambers and

many could go out of the exhaust stack in this state. A low pressure of atomizing air is used to

provide atomizing air through supplementary orifices and this stream of atomizing air breaks the

fuel up into fine mist permitting effective ignition and combustion. It is necessary therefore that

the atomizing air system be operative form the time of ignition firing through acceleration and

through operation of the turbine. The operation of the atomizing air system can be divided to

three conditions; 100% gas fuel, 100% distillate and dual fuel operation.

2.2 System Overview

Air for the atomizing air system is supplied from the 17th

of the compressor. This air,

which is obtained from here, is also known as the compressor discharge pressure. Before the air

enters the system, it is cooled to the desired temperature for atomizing to take place by heat

exchangers. The air then is passed through filters to eliminate any foreign particles from the

compressor. When the turbine is first fired, the accessory gear is not rotating at full speed and the

main atomizing air compressor is not outputting sufficient air for proper fuel atomization. During

this period, the starting (booster) atomizing air compressor driven by an electric motor is in

operation supplying the necessary atomizing air. The starting atomizing air compressor at this

time has a high-pressure ratio and is discharging through the main atomizing air compressor,

which has a low-pressure ratio. The main atomizing air compressor pressure increases with the

increasing speed of the turbine and at approximately 60% of the full speed the main compressor

pump starts to function. Once the turbine reaches 95% of its full speed, the starting compressor

will automatically shut off and the main compressor takes over fully to supply atomizing air.

When the gas turbine is running on 100% gas fuel, the purge air system takes place

whereby, the purge air is used to flush the fuel nozzles in case there is any distillate left on the

nozzles. If there is distillate left on the nozzle, then the nozzles will get choked up. The purge air

also serves as a cooling medium for the combustion canisters because the temperature can be

very intense when combustion takes place. On the other hand, when the gas turbine is operating

on 100% distillate flue, the atomizing air is used to break up the distillate into fine mist. In this

way, combustion can take place very efficiently.

Figure 2. 1: The Combustion Canisters And The Four Different Tubes That Are Going Into It

The innermost tube that goes in from the side is the gas fuel tube where else, the tube just

above it supplies atomizing air. The tube that runs directly into the combustion canister is the one

that supplies distillate and the tube that is fixed to the distillate tube supplies purge air.

2.3 Cooling & Sealing Air System

The cooling and sealing air system provides the necessary air flow from the gas turbine

compressor to other parts of the gas turbine to prevent excessive temperature buildup in these

parts during normal operation and for sealing of the turbine bearings. Atmospheric airs from off-

base centrifugal type blowers are used to cool the turbine exhaust frame. The cooling and sealing

functions provided by the system are as follows:

Sealing of the turbine bearings

Cooling of internal turbine parts subjected to high temperature

Cooling of the turbine outer shell and exhaust frame

Providing an operating air supply for air operated valves

Compressor pulsation

Cooling of the turbine third stage shroud

The cooling and sealing air system consists of specially designed air passages in the

turbine casing, turbine nozzles and rotating wheels. Besides that it has also special piping for the

compressor extraction air and associated components.

a. Externally Piped Extractions

Cooling and sealing air provided form two connections on the compressor casing

at the fifth stage and is piped externally to each of the three turbine bearings. The

centrifugal dirt separator located in the fifth stage piping removes any particles of dirt or

foreign matter that might be injurious to the bearings. The pressurized air, cools the

bearings by containing any lubricating fluid within the bearing housing that otherwise

might seep past the mechanical seals. Cooling air is also provided from two connections

on the compressor casing at the fifth stage, which is piped externally to cool of the

turbine third stage shroud.

The pressure, speed and flow characteristics of the gas turbine compressor are

such that air must be extracted form the 11th

stage and vented to the atmosphere. This is

done to prevent the pulsation of the compressor. It is done during the acceleration period

of the turbine starting sequence and during deceleration of the turbine at shutdown. This

air is extracted at four flanged connections that can be found at the 11th

stage of the

compressor.

b. Exhaust Frame Blowers

The cooling for the turbine shell and the exhaust frame struts are provided by 2

motors operated centrifugal blowers (88TK-1 & 88TK-2). These motors are rated at

100hp with a 3-phase supply of 380V at a frequency of 50Hz. Each motor contains a

60Watt heater in order to protect the motors from moisture. This air is externally piped

from the blowers to the turbine area. Both blowers are usually in operation when the gas

turbine is running. If the pressure in the turbine compartment decreases, an alarm will be

annunciated and the turbine will continue to run with one blower in service but with

reduced cooling airflow. If both motor fails then the SPEEDTRONIC Mark V control

system will automatically initiate a normal shutdown sequence.

c. Internal Extractions

Air is extracted from the 16th

stage pf the rotor through a space between the 16th

and the

17th

stage compressor wheels. This air passes through the rotor bore to the turbine section

for cooling of the 1st and 2

nd stage buckets.

Compressor discharge air is used to cool the first and second stage turbine nozzles. It is

also used as source of air for operating various air-operated valves in other systems.

The picture below shows the exhaust frame blower that can be found at the gas turbines.

The netting like opening on the top of the structure is used to suck in air and also filter the air

from unwanted particles that are large in size.

2.4 Cooling Water System

The cooling water system is a pressurized closed system that is designed to accommodate

the heat dissipation requirements of the turbine and generator, the generator cooling system, the

atomizing air precooler and the turbine supports. The cooling water system is comprised of both

on-base and off-base mounted components. The on-base components include the lube oil heat

exchangers in the accessory compartment base, atomizing air heat exchangers, turbine aft

supporting legs, heat exchangers of the generator‟s hydrogen cooling system and flow regulating

valves. The off-base components include one industrial type cooling water tower, two water

pumps and other flow controlling devices. The on-base components are installed within the gas

turbine unit itself but the off-base components are located at a separate place. The cooling water

system circulates water as a cooling medium to cool several turbine generator components and

maintain the lubricating fluid at an acceptable temperature. The operation of the cooling water

system is depicted as following: -

Cooling water is first circulated through the four generator heat exchangers (coolers) of

the hydrogen cooling system to remove the heat that is being dissipated by the hydrogen

gas. If there isn‟t sufficient water to cool the hydrogen gas, the gas in return can become

very hot and combustible.

Cooling water then circulates through the lube oil heat exchangers to keep the lubricant in

the lubrication system at the required temperature setting for effective lubrication of the

bearings.

The next destination would be the water jackets surrounding the turbine support legs. If

this not cooled, the turbine support legs could expand and cause misalignment between

the gas turbine and generator.

Finally, the cooling water is circulated through the atomizing air precooler.

After performing its cooling function, the water is circulated to the off-base industrial

cooling water module where it is cooled before it is recirculated. The hot water will go through a

series of radiator fins whereby there are fin fans installed below the fins to cool the water. Water

is pumped through the cooling water system and back through the radiators by the A.C operated

cooling water pumps. There are two pumps whereby one function as a standby for the other one.

There is also a temporary tank that is filled with water to accommodate the shortage of cooling

water in case the temperature of the various compartments stated above does not decrease to the

ideal value

The picture below shows the cooling water. The radiator fins are in the green compartment

where else the fin fans are installed below the compartment.

2.5 Gas Fuel System

Gas Fuel System is designed to deliver gas fuel to the turbine combustion chambers at the

proper pressure and flow rates to meet all of the starting, accelerating and loading requirements

of the gas turbine. Gas fuel from Petronas passes through a metering system and a strainer prior

to flowing through the gas valves and into the gas manifold piping. The gas fuel flow to the

turbine is pressure-regulated and controlled by the stop/speed ratio valve (SRV) and the gas

control valve (GCV) to supply the required flow to the gas turbine combustion system. Both the

valves are combines in one assembly. They are both single-action electro hydraulically operated

with spring-loaded-to-close-valve plugs.

Gas Stop/Speed Ratio Valve (SRV)

This valve provides fuel shutoff when required in normal operation or during emergency

conditions.

Gas Control Valve (GCV)

The function of this valve is to meter the proper amount of fuel required by the turbine

for ja given load or speed.

Gas Strainer

This strainer removes foreign particles that might be in the incoming fuel gas. A blow

down connection on the bottom of the strainer provides for periodic cleaning of the

strainer screen. Frequency of cleaning will depend on the quality of the fuel being used.

The gas strainer has a small drain like compartment at the foot of the strainer that is filled

with water. The foreign particles that are much more heavier than the natural gas will

drop into the water. The water is cleaned every two months.

The picture below displays the gas strainer or also known as the gas scrubber that is used to

eliminate the moist in the gas. The pipe jetting out above is used to vent out whatever mist that

can be found in the gas.

2.6 Hydraulic Oil System

The Hydraulic Oil supplies the required fluid power used to operate the control

components of the gas turbine fuel system. This fluid furnishes the means for opening or

resetting of the fuel stop valves, in addition to the variable turbine inlet guide vane and the

hydraulic control and trip devices of the gas turbine. The main components of the hydraulic oil

system are the main hydraulic supply pump, an auxiliary supply pump, the system filters, an

accumulator assembly and the hydraulic supply manifold. Regulated, filtered lube oil from the

bearing header of the gas turbine is used as the high-pressure fluid necessary to meet the

hydraulic system requirements.

a) Main Hydraulic Supply Pump

A pressure compensated variable displacement pump, driven by the shaft of the

accessory gear is the primary pump that pumps oil from the lube oil system for the

hydraulic oil supply. The fluid supply is taken from the bearing headers after the fluid

is filtered at the lube oil filters.

b) Auxiliary Hydraulic Supply Pump

This pump operates as a backup whenever the main hydraulic pump pressure output

level is inadequate for turbine operation. Usually this condition arises during the

startup or when the turbine is at a low speed. When the main pump operating fails to

maintain adequate pressure, the pressure switch 63HQ-1 will sense the condition and

the auxiliary pump will be started by a signal from this switch.

c) Hydraulic Supply Manifold

Hydraulic fluid is pumped to the hydraulic supply manifold. This manifold is an

enclosure designed to provide a means of interconnecting a number of small

components. Contained within the manifold assembly are relief valves, air bleed

valves and check valves. Each pump has a pressure compensator built into it, which

regulates pressure. The relief valves will relieve the pressure should the pressure

regulator fail and the check valves will prevent the oil from flowing into the out-of-

service pump. The check valves also keep the hydraulic lines full when the turbine is

shut down. The air bleed valves on the other hand vent any air present in the pump

discharge lines.

d) Hydraulic Oil Filters

The hydraulic supply system filters prevent contaminants from entering the control

devices of the inlet guide vane system, the fuel control system, the fuel control servo

valves and other hydraulic devices. The dual filter assembly complete with fill valve

and transfer valve is provided to permit changeover to the second filter without

interrupting the operation of the system. Differential gauges are provided to indicate

the oil pressure across the filters and when the gauge indicates a low pressure, the

filter cartridge is changed.

e) Hydraulic Accumulator Assembly

A hydraulic accumulator assembly, having two accumulators is also connected in the

high-pressure line of the hydraulic supply system to absorb any severe shock that may

occur when the supply pumps are started. These accumulators are charged with

nitrogen gas.

The output of the hydraulic supply system is a high-pressure control fluid that interfaces

with the turbine control and protection system. This high-pressure supply fluid is also used as

hydraulic fluid in the variable inlet guide vane actuating cylinders and the IGV (Inlet Guide

Vane) control.

This picture below depicts the inlet guide vane.

The inlet guide vane controls the amount of air that is coming into the compressor from

the air intake system. The maximum angle that the inlet guide vane can open is 840 and the

minimum angle is 340. The inlet guide vane is at maximum angle when the machine is on load

and at this time, more hydraulic fluid is sent to the inlet guide vane.

2.7 Inlet and Exhaust Systems

2.7.1 General Overview

Gas Turbine performance and reliability are a function of the quality and cleanliness if

the inlet air entering the turbine. Therefore, for most efficient operation, it is necessary to treat

the atmospheric air entering the turbine and filter out contaminants. It is the function of the air

inlet system with its specially designed equipment and ducting to modify the quality of the air

under various temperature, humidity and contamination situations and make it more suitable for

the use in the unit. Hot exhaust gases produced as a result of combustion in the turbine are

cooled and attenuated in the exhaust system ducting before being released to the atmosphere.

These exhaust emissions must meet certain environmental standard of cleanliness and acoustic

level depending on the site location. The noise generated during gas turbine operation is

attenuated by means of absorptive silencing material and devic4s built into the inlet and exhaust

sections which dissipate or reduce the acoustical energy to an acceptable level.

2.7.2 Air Inlet System

The air inlet system consists of a multi-stage filter house and support structure, inlet

ducting system and inlet plenum leading to the compressor section of the turbine. Inlet air enters

the inlet compartment and flows through the ducting, with built in acoustical silencer and trash

screen, to the inlet plenum and into the turbine compressor. The elevated intake arrangement

provides a compact system and minimizes the pickup of dust concentrated in the air near ground.

All external and internal surface areas of the inlet systems are coated with a protective corrosion-

inhibiting primer or galvanized for corrosion protection. The main components of the Air

Filtration System are Weather Hoods, Trash Screen, Moisture Eliminator Blades, Pre-Filters

(Moisture Coalesces) and Final Filters.

Component Function

Weather Hoods

The air intake at each end of the compartment is fitted with large weather

hoods. These hoods minimize the ingestion of rainwater into the inlet

compartment during rainy conditions.

Trash Screen Consists of wire cloth that will block large objects from entering the filter

modules. These trash screens are mounted vertically.

Moisture

Eliminator Blades

Consists of a series of vertically oriented, hooked vanes mounted parallel to

the airflow. These vertical louvers that are shaped „W‟ further eliminate

rainwater droplets that manage to enter the air intake system.

Pre-filter /

Coalescer

It is a non-woven disposable pad that is approximately 1 inch thick made

from synthetic fiber. This pad captures smaller droplets that were not

removed by the moisture eliminator. As a filter, it collects the larger dirt

materials to extend the life of the final filter and as a coalescer, it traps the

smaller droplets of water that were not caught by moisture eliminator. There

are 288 pre-filters in an air intake house.

Final Filter The final stage before the air goes to the compressor and this filter has the

ability to remove the dust particles as small as 1 micron from the air.

The picture below displays the air intake house where the air from the atmosphere is absorbed

when the machine is running.

2.8 Liquid Fuel System

This liquid fuel system is a factory assembly unit. It consists of the off base fuel

forwarding skid that pumps the fuel from storage tank to the gas turbine accessory base at the

required pressure, temperature and flow rate. It is used to transfer distillate fuel oil from an

aboveground storage facility to the gas turbine. This liquid fuel is distributed to the 14 fuel

nozzles of the combustion system. The fuel system filters the fuel and divides the fuel flow into

14 equal parts for distribution to the combustion chambers at the required flow rate and pressure.

When starting on liquid fuel, the fuel-forwarding pump is automatically started when the unit is

given a start signal. The liquid fuel system is comprised of the following components:

a) Low Pressure Fuel Filters

The dual low-pressure on-base fuel oil filters will filter the low-pressure fuel oil from

the fuel forwarding system. The filters consist of 5-micron pleated-paper elements.

b) Fuel Oil Stop Valve

This is an emergency valve operated from the protection system, which shuts off the

supply of fuel to the turbine during normal or emergency shutdowns. This valve is a

special purpose, two-position valve with a venturi disc and valve seat. When the

turbine is shutdown in the normal sequence or by an emergency or over speed

condition, the fuel oil stop valve will fully close within 0.5seconds. During normal

operation of the turbine, the stop valve is held open by high-pressure hydraulic oil

that passes through a hydraulic trip relay valve.

c) Flow Divider

Flow divider divides the single stream of fuel from the pump into 14 separate

streams, one for each combustor. The continuous-flow free wheeling flow divider

consists of 14 gear pump elements in a circular arrangement having a common inlet

with a single timing gear. This timing gear serves to maintain true synchronous speed

of each pumping element with all other elements. The flow divider is driven by the

pressure differential between its inlet and outlet.

d) Check Valves

There is a check valve in each line between the flow divider and the fuel nozzles.

These valves are mounted near the input connection of the nozzles. These valves

serve as „anti-dribble‟ valves to prevent fuel oil from continuing to flow after the fuel

pump is disengaged so there will be a clean cutoff of fuel to the nozzle. They also

prevent purge air from entering the liquid fuel system.

e) False Start Drain Valves

In the event of an unsuccessful start, the accumulation of combustible fuel oil is

drained through false start drain valves provided at appropriate low points in the

combustion/turbine area. The false start drain valve, which is normally open, closes

as the turbine accelerates during the startup. Air pressure from the discharge of the

unit‟s axial flow compressor is used to actuate this valve. During the turbine

shutdown sequence, the valve opens as compressor speed drops.

f) Fuel Forwarding Skid

The fuel-forwarding pump is used to supply distillate fuel from the storage tanks to

the gas turbine. The amount of distillate that is being used will be displayed on the

meter at the pump.

g) Fuel Unloading Skid

The fuel-unloading pump is used to transfer the distillate fuel from the oil tankers.

The picture below displays the Fuel Forwarding Skid area. The piping shown in the picture is the

ones that connect the storage tank and the gas turbine through the fuel-forwarding pump. There

are four forwarding skid altogether.

The picture below displays the Fuel Unloading Skid area. Once the fuel is unloaded from the

tanker, it goes straight into storage tank. There is a meter that displays the amount of distillate

that is being sent into the tank. There are four unloading skid altogether.

This picture shows the storage tanks where the fuel is kept for a temporary time till it is used.

The tanks are in a compound called „Dyke‟ that can contain 110% of distillate if the tank cracks

and the distillate spills. This ensures no distillate will flow down to the plant if an explosion

takes place.

2.9 Lubrication System

The lubrication requirements for the gas turbine power plant are furnished by a common

forced-feed lubrication system. This lubrication system complete with tank, pump, coolers,

filters, valves and various control and protection devices, furnishes normal lubrication and

absorption of heat rejection load of the gas turbine. Lubricating fluid is also circulated to the

three main turbine bearings and to the turbine accessory gear. Also, lubricating fluid is supplied

to the starting means torque converter for use as hydraulic fluid as well as lubrication.

Additionally, a portion of the pressurized fluid is diverted and filtered again for use by hydraulic

control devices as control fluid. Lubricating oil and seal oil is also provided to the generator

bearings from this system. The lubrication system also provides the source of oil to run the trip

oil system, which is very essential when it comes to protecting the gas turbine in case of a faulty.

Major system components include: -

a) Lube Oil Tank

The reservoir and sump for the lubrication system is the 3300-gallon (12,486.24L)

tank, which is fabricated as an integral part of the accessory base. Lubricating oil is

pumped from the reservoir by the main shaft driven pump or auxiliary lube oil pump

or the emergency lube oil pump to the bearing header, the accessory gear, the

generator and the hydraulic supply system. After lubricating the bearings, the

lubricant flows back through various drain lines to the lube reservoir.

b) Main Lube Oil Pump

Lubricating oil is supplied from the lube oil tank to the bearing header, the accessory

gear, generator bearings and the hydraulic supply system through the main lube oil

pump after the shaft reaches 95% of its full speed which is about 2850r.p.m. At this

speed the pressure provided by the shaft driven lube oil pump is high enough to

provide the lubrication for the necessary components.

c) Aux. Lube Oil Pump

The auxiliary lube oil pump is a submerged centrifugal type pump that supplies

lubricating oil from the lube oil tank to the bearing header, the accessory gear,

generator bearings and the hydraulic supply system from the time the shaft starts to

rotate till the shaft reaches 95 % of its full speed. This pump also functions when the

shaft is rotating slowly at about 50 – 60r.p.m during the cool down stage. The cool

down stage is important in order to prevent the shaft form bending due to thermal

stress inflicted by the high temperature. This pump is a 100hp, 380V AC motor

driven pump.

d) Emergency Lube Oil Pump

The emergency lube oil pump is a submerged centrifugal type pump that supplies

lubricating oil from the lube oil tank to the bearing header during an emergency

shutdown in the event the auxiliary lube oil pump has been forced out of service

because of loss of A.C power, or for other reasons. This pump is a 10hp, 120V DC

motor driven pump.

e) Mist Eliminators

Mist eliminators are mounted at the left side of the accessory base and it consists of a

tank filled with fiberglass media. As the vent air flows upward through the media, any

oil mist coalesce on the fiber glass will form oil droplets that will drain out through

the bottom of the tank before the air goes to the atmosphere. The drain will go back to

the oil tank.

f) Oil Coolers / Heat Exchangers

The lube oil is cooled by shell and tube, oil to water heat exchangers. The water flows

through the U shaped finned tubes with the oil flowing on the shell side. Two cooler

assemblies are mounted in each side of the oil tank. A transfer valve is located

between both the coolers. The transferring between one cooler to another cooler is

done step by step. The two coolers are connected by a fill and pressurizing valve that

is opened prior to transferring the coolers. Each cooler shell is provided with a drain

valve. Normal application is with one cooler in service thus maintenance work on the

other cooler can be done at any time. The lube oil header temperature is maintained

by controlling the flow of water through the cooler and the normal operating

temperature is 55C. If at all the temperature of the lube oil increases more than the

normal operating temperature, the machine will not start operating.

g) Oil Filters

Filtration of all lube oil is accomplished by a 5-micron, pleated-paper filter installed

in the lube system just after the lube oil heat exchanger. The dual filters are used with

a transfer valve installed between the filters to direct oil flow through either filter and

into the lube oil header. Only one filter will be in service at a time; thus cleaning,

inspection, and maintenance of the second one can be performed without interrupting

oil flow or shutting the gas turbine down. A differential pressure gauge is connected

across the filters to indicate when the filter element needs replacement. Filters are

usually changed when the differential pressure gauge indicates a differential pressure

of 15psi(103.47kPa).

h) Pressure Regulation

Two regulating valves are used to control the lubrication system pressure. A

backpressure relief valve, VR1 limits the positive displacement main pump discharge

header pressure and relieves excess fluid to the lube reservoir. The lube pressure in

the bearing header is maintained at approximately 25psi(172.36kPa) by the

diaphragm-operated regulating valve, VPR2. The diaphragm valve is operated by

sensing fluid pressure in the bearing header.

2.10 Seal Oil System

Seal Oil System provides the sealing of hydrogen gas inside the generator compartment

for safety purposes. It acts as the sealing between the hydrogen-cooled generator and the 4th

bearing that is located at the turbine end of generator compartment. As hydrogen purity of

approximately 75% in air is explosive the need for this complicated seal oil system arises. If the

hydrogen purity level reaches 82.5%, an alarm will be annunciated and the machine will trip if

the purity level reaches 75%. The hydrogen gas is supplied through the hydrogen gas pallets that

are kept outside each unit in a shaded area. Below are some of the major equipments that are

involved in this seal oil system: -

a. Auxiliary Seal Oil Pump

This 7.5 hp AC motor that is supplied with 380V produces the pressure needed to seal

the hydrogen-cooled generator until the Auxiliary Lube Oil Pump takes over. This

pump starts functioning when the gas turbine is on standstill.

b. Emergency Seal Oil Pump

This 7.5 hp DC motor that is supplied with 120V produces the pressure needed to seal

the hydrogen-cooled generator in case of emergency shutdown such as power failure or

when electrical maintenance work is being done whereby the power supply must be

switch off. This pump would take over the role played by the Auxiliary Seal Oil Pump

in case any of the above conditions arises.

c. Bearing Drain Enlargement

This drain is used to release any contaminant gases in the seal oil. There is usually a

small percent of hydrogen gas that can be found in the seal oil and this gas has to be

eliminated before the seal oil returns to the main lube oil tank.

d. Seal Drain Enlargement

There are 2 seal drain enlargement whereby one is at turbine end while the other is at

collector end of the generator compartment. These drains are also meant to release any

contaminant gases in the seal oil.

e. Differential Pressure Regulator

This regulator maintains the pressure of the seal oil to be higher than the hydrogen at

approximately 5.5psi. This way, the hydrogen gas cannot seep out to the atmosphere.

Alarm will be annunciated if the pressure drops to 4.5psi and the purge shutdown will

occur if the pressure drops to 3.5psi. The seal oil pressure at the 4th

and 5th

bearing is

usually around 35bar but this pressure is not constant due to the fact it depends on the

hydrogen pressure.

f. Carbon Dioxide Skid Manifold

Carbon Dioxide is used to purge all the hydrogen gas in the generator compartment

whenever the purity level drops to a hazardous level. The carbon dioxide gas tanks that

are kept at the manifold supply the carbon dioxide gas.

g. Float Trap

Float trap is used to collect any seal oil that might have leaked. If there is any

accumulation of oil in the float trap then an alarm will be annunciated.

This picture below depicts the bearing drain enlargement that is fixed on the generator

compartment itself. The pipe from the left is coming from bearing No.4 and the pipe from the

right is coming from bearing No.5.

The picture below displays the seal drain enlargement that can be found at the end of the

generator section and the load tunnel.

The picture below shows the Carbon Dioxide Skid that is installed in from of the generator

compartment.

This picture shows the hydrogen pallets that supply hydrogen gas to the generators and the

pressure and amount of hydrogen gas that is being supplied are controlled by pressure regulating

valves that can be seen on the left of the pallets.

2.11 Starting System

Before the gas turbine can be fired and brought to operating speed, it must first be rotated

or cranked by accessory equipment. This is accomplished by an induction motor, operating

through a torque converter to provide the cranking torque and speed required by the turbine for

start-up. Also at shutdown, this same equipment continues to rotate the turbine rotor at slow

speed for cool down purposes. The starting system consists of an induction motor and torque

converter coupled to the accessory gear. The cranking motor is 1250hp A.C motor that is

supplied with 6.6kV at 50Hz and the maximum speed it can rotate is 3000r.p.m. Switches 33TM-

1, 33TM-2, 33TM-3 and 33TM-4 are used to gradually increase the speed of the turbine, where

else switches 33TM-7 and 33TM-8 is used to determine the speed for the purging cycle and the

acceleration period for the shaft respectively. Switches 33TM-5 and 33TM-6 are reserved as

spares in case the any one of the functioning switches fail. These switches will control the

amount of lube oil that is used to energize the solenoid valves 20TU-1 and 20TU-2. These

solenoid valves are the ones that control the cranking motor, 88CR and the torque converter,

88TM.

Cranking and turning power are both supplied by the starting system during gas turbine

start-up and shutdown cycles. In the starting cycle there are three primary functions provided by

the starting equipment which is start the gas turbine rolling, accelerate the gas turbine to a speed

where it can be fired and after the turbine has been fired, further accelerate it to a self sustaining

speed. Initially the gas turbine is in the standstill mode after it has been cooled down for a period

of 24 – 48 hours. The self-sustaining speed is defined as the speed at which the gas turbine

develops net positive power output. At this speed the gas turbine can rotate without the cranking

motor. TNH is defined as the speed of turbine.

The start-up sequence from standstill of the machine until the time it is synchronized with

the national grid is depicted below: -

a. When the START signal is given, the cranking motor is started and the solenoid valve,

20TU-1 is energized and at the same time, the starting motor 88CR is energized.

b. Solenoid Valve, 20TU-1 controls the position of the fill and drain valve for normal start-

up operation of the torque converter. When it is energized, it pressurizes the operator

from no fill, full drain position to full fill position. The orifice in the drain line determines

the quantity of fresh cool oil that flows into the torque converter.

c. The circulating oil inside the torque converter will provide some kind of turbulence that

will start turning the shaft when the required minimum torque is achieved. Thus the

torque converter is providing the breakaway power for the turbine to start rotating.

d. Speed will increase as the machine goes through purging cycle to purge all the unburned

fuel or gas that might be inside the turbine compartment. Speed will increase to 25 %

TNH before 20TU-1 de-energizes thus reducing the speed to 9.25% TNH. Here the limit

switch, 33TM-8 is the one that does the deenergizing of the solenoid.

e. After reaching approximately 9.25% TNH, speed of the machine will start to increase

again and at 10% TNH, the firing sequence will occur. The gas valve will open and the

ignition process will occur. The setting for the speed of the machine to start increasing

again is controlled by the 33TM-7 switch.

f. If 2 or more flame detectors fail to pick up then the machine will fail to start. Restarting

of the machine can only be done maximum number of three times.

g. Speed will increase to 60% TNH. This is the self-sustaining speed meaning the turbine

develops a net positive output. It means the turbine will be able to rotate on its own

without the assistance of the cranking motor. At this moment, the 20TU-1-solenoid valve

will de-energize and hence the cranking motor, 88CR and the torque converter, 88TM

will also stop functioning.

h. Speed will increase all the way up to 95% TNH whereby the 2 Exhaust Frame Blower

will start operating. Auxiliary Lube Oil Lump stops and its function to provide

lubrication to the system will be taken over by shaft driven Lube Oil Pump.

i. After machine reaches full speed no load at 100% TNH then the machine is ready for

synchronizing with National Grid System.

j. Synchronizing with the National Grid System is done automatically by the

SPEEDTRONIC Mark V control system. All the factors necessary for synchronizing

must and will be monitored and controlled automatically such as: -

- Frequency

- Voltage

- Phase Sequence

- Phase Angle

k. After the turbine has been on run, the rotor must be put on turning gear type operation to

avoid thermal bow in the rotor. Turning the rotor slowly until it cools ill ensure that the

metal temperature remains uniform. This will avoid the metal from suffering rotor bow.

Rotor bow will occur if the top surface is hotter than the bottom surface. Starting of the

turbine in this condition will cause high vibration.

The picture below depicts the cranking motor and the torque converter, which can be found in

the accessory compartment.

Lubrication oil is supplied to turn the torque converter when the gas turbine first starts

turning till it reaches 1800r.p.m. As the speed increases, more oil is supplied to the turn the

torque converter.

2.12 Trip Oil System

The gas turbine protection system consists of number primary and secondary systems,

several of which operate at each normal startup and shutdown sequence. This trip oil system is

the primary protection interface between the turbine control and protection system circuits

(SPEEDTRONIC Mark V Control System) and the components on the turbine, which admit or

shut fuel to the turbine. This system contains devices that are electrically operated as well as

others that are completely mechanical devices that operate directly on the turbine components.

Low-pressure oil taken from the turbine‟s lube oil system is used as the trip oil. Lube oil

is passed through a piping orifice to become the trip oil. The orifice is located in the pipe running

from the bearing header supply to the trip oil system. This orifice is sized to limit the flow of

lube fluid into the trip oil system and insure an adequate capacity for all tripping device

operations without causing a starvation of the lube oil system when the trip oil system is

activated.

Orifice check valves assemblies are installed in the trip oil lines to the liquid fuel stop

valve and the gas fuel stop valve to permit the operation of either one of the systems when the

other one is tripped. It also permits IGV operation during over-speed trip, manual trip or when

either one of the fuel system is trip state.

The devices that cause turbine shutdown through the trip system do so by dumping fluid pressure

from the system through solenoid dump valves: -

a. Hydraulic Dump Solenoid Valve – 20TV

b. Gas Fuel Stop Valve – 20 FG

c. Liquid fuel Stop Valve – 20FL

When the oil in the trip line is dumped then the valves will close by spring return action.

When the turbine is started the dump valves are energized to reset at the desired point in the

starting sequence.

a. Over speed Trip Mechanism (BOS)

This totally mechanical device located in the accessory gear is actuated

automatically by the over speed bolt should the turbine speed exceed the bolt

setting. As a result, a rapid decay of trip oil pressure (OLT) occurs ultimately

stopping the flow of fuel to the turbine by action of the fuel stop valve.

b. Solenoid Dump Valves

- Hydraulic Dump Solenoid Valve – 20TV

Solenoid-operated, spring-return hydraulic dump valve 20TV is used to

trip the system operation by a signal from the master control and its

protection circuit. The valve is energized when the turbine is running. It

dumps the trip oil pressure to the inlet guide vane (IGV) valve and stops

the fuel flow in a manner similar to the over speed trips.

- Gas Fuel Stop Valve – 20FG

Solenoid valve 20FG is a spring biased spool valve, which dumps trip oil

pressure to drain causing the stop/ratio and gas control valves to trip shut.

This solenoid valve is spring biased to trip therefore it protects the turbine

during all normal situations as well as for loss of dc power.

- Liquid Fuel Stop Valve – 20FL

Solenoid valve 20Fl is a spring biased spool valve, which relieves trip oil

pressure causing the liquid fuel stop valve to trip shut. This solenoid valve

is spring biased to trip therefore it protects the turbine during all normal

situations as well as for loss of dc power.

c. Variable Inlet Guide Vane System

The modulated inlet guide vane system is activated by the action of the trip oil

system using low-pressure trip oil in conjunction with high-pressure oil from the

hydraulic supply system. Electronic control signals activate and position the inlet

guide vanes, both during normal operation and under trip conditions through the

action of the servo valve, 90TV, hydraulic dump valve, VH3 and position sensors,

96TV-1 and 96TV-2. When the turbine is at rest, the inlet guide vane angle

position is at the designated closed position. This closed guide vane angle is the

position established to limit the airflow through the compressor during the turbine

accelerating and decelerating sequence.

2.13 Compliance To Rules And Regulation

The employer is advised to comply with the followings requirements under the Occupational

Safety and Health (Use and Standards of Exposure of Chemicals Hazardous to Health)

Regulation 2000;

a. Eight-hour time-weighted average

Regulation 7(1)

An employer shall ensure that the exposure of any person to any chemical hazardous to

health listed in scheduled 1 in any eight hour work hour work shift of a work does not

exceed the eight-hour-time-weighted average airborne concentration specified for that

chemical in that schedule.

b. Action to control exposure

Regulation 15 (1)

The employer shall control chemicals hazardous to health through the following control

measures;

a) Elimination of chemicals hazardous to health from the place of work

b) Substitution of less hazardous chemicals for chemicals hazardous to health

c) Total enclosure of the process and handling systems

d) Isolation of the work to control the emission of chemicals hazardous to health

e) Modification of the process parameters

f) Application of engineering control equipment

g) Adoption of safe work systems and practices that eliminate or minimize the risk to

health

h) Provision of approved personal protective equipment

Regulation 15 (2)

The employer shall ensure that all safe work systems and practices are documented and

implemented.

Regulation 15 (3)

The employer shall ensure that all safe work systems and practices are reviewed

whenever there is a significant change to the process, equipment, materials or control

measures installed.

c. Use of approved personal protective equipment

Regulation 16 (1)

Approved personal protective equipment shall be used

a) Where the application of control measures specified in paragraphs 15 (1)(a) to (g)

would be impracticable

b) As an interim measure while other preferred control measures are being design and

installed

c) Where the measures taken to comply with paragraphs 15 (1)(a) to (g) do not

adequately control an employee‟s exposure to chemicals hazardous to health

Regulation 16 (2)

Where the approval personal protective equipment is used to control exposure to

chemicals hazardous to health, the employer shall establish and implement procedures on

the issuance, maintenance, inspection and training in the use of the approved personal

protective equipment.

Regulation 16 (3)

The approved personal protective equipment provided to employees pursuant to sub

regulation (1) shall;

a) Be suitable to the type of work in which they are employed

b) Fit the employees

c) Not adversely affect the health or medical condition of the employees

d) Be in sufficient supply and readily available to employees who require it

d. Engineering control equipment

Regulation 17 (1)

Any engineering control equipment provided as described under section 5 (b) Action to

control exposure, regulation 15 (1), sub item (f) in this report, shall be

a) Inspection at an appropriate intervals by the employer, each interval being no longer

than one month

b) Examined and tested for its effectiveness by a hygiene technician at appropriate

intervals, each intervals being no longer than twelve months

e. Duty of employer to ensure Labeling

Regulation 20 (1)

An employer shall ensure that all chemicals hazardous to health supplied or purchased by

him and used in the place or work are labeled and that the labels are not removed,

defaced, modified or altered.

Regulation 20 (2)

When the labels mentioned in sub regulatio (1) are removed, defaced, modified or altered

while the chemical hazardous to health is being used at the place of work, employer shall

re label the chemical

f. Duty of employer to ensure Re Labeling

Regulation 21 (1)

When a chemical hazardous to health is transferred to another container, others than that

in which it was originally supplied, and the contents of that container are not used within

a normal work shift, the employer shall ensure that container is relabeled.

Regulation 21 (2)

If the content of the container referred to in sub regulation (1) are used within a normal

work shift, the employer shall ensure that container is relabeled with the chemical name

or the trade name as written on original label.

g. Information, instruction and training

Regulation 22 (1)

An employer who undertakes work which may expose or is likelu to expose his

employees to chemicals hazardous to health shall provided the employees with such

information, instruction and training as may be necessary to enable them to know:

a) The risk to health created by such exposure

b) The precautions which should be taken

Regulation 22 (3)

The employer shall review and conduct the training programme

a) At least once in two years

b) If there is a change in the hazard information on the chemiclas hazardous to health,

safe work practices or control measures

c) Each time employees are assigned to new tasks or new work areas where they are

exposed or likely to be exposed to chemical hazardous to health

h. Monitoring of exposure

Regulation 26 (2)

If an employee is exposed or likely to be exposed to chemicals hazardous to health listed

in schedule II, the monitoring of exposure of employee determined in sub regulation (I)

shall be repeated at intervals of not more than six months or at such shorter intervals as

determined by the assessor and the monitoring of exposure shall continue at this

frequency until such time the assessor is satisfed that further monitorng of exposure is no

longer required.

Regulation 26 (4)

The employer shall maintain in good order and condition any record or summary of the

record of any monitoring carried out for the purpose of these regulation an shall be kept

available:

a) Where the record is representative of the personal exposure of a person exposed to

any chemicals hazardous to health, for at least thirty years

b) In any others case, for at least five years

i. Warning sign

Regulation 29 (1)

Where a chemicals hazardous to health is used in any area in any manner that is

hazardous to health of any person who may be in that area or who may be or is likely to

be at risk of being effected by the chemicals hazardous to health, the employer shall

ensure that;

a) Warning signs are posted at a conspicuous at every entrance of the area to warn

persons entering the area of the hazard

b) Others relevant information is given to persons who may be or are likely to be at risk

of being affected by the chemicals hazardous to health

Regulation 29 (2)

The employer shall ensure that the warning signs required by these regulations are

illuminated and cleaned as necessary so that the legend is readily visible.

Regulation 29 (3)

For the purpose of sub regulation (1), the warning shall

a) Give warning of the hazards

b) Be written in the national language and English language

c) Be printed in dark red against white background

j. Health surveillance programme

Regulation 27 (1)

Where an assessment indicates that health surveillance is necessary for the protection of

the health of employees exposed or likely to be exposed to chemicals hazardous to health,

the emplyer shall carry out a health surveillance programme.

Regulation 27 (2)

The medical surveillance component of the health surveillance programme in

subregulation (1) shall be carried out by an occupational health doctor.

Regulation 27 (3)

If an employee is exposed or likely to be exposed to chemicals hazardous to health listed

in Schedule II, the health surveillance required under sub regulation (1) shall include

medical surveillance conducted at intervals of not more than twelve months or at such

shorter intervals as determined not more than twelve months or at such shorter interals as

determined by the occupational health doctor or an occupational safety and health officer

who is also a medical practitioner.

Regulation 27 (4)

The employer shall ensure that the health surveillance record or a copy thereof is

maintained in good order and condition and kept for a period of a thirty years from the

data of the last entry made in it.

Regulation 27 (5)

The employer shall make available upon request all records required to be maintained

under sub regulation (3) to the Director General for examination and inspection.

Regulation 27 (6)

The employer shall, after a reasonable notice being given, allow any of his employees‟

access to the health surveillance record which related to the employee.

2.14 Recommendation

Based on the findings derived from the monitoring program, Port Dickson Power Berhad is

encouraged to continue these good practices with special emphasize on the following;

i. Use of approved Personal Protective Equipment (PPE)

a. Respirator

The approval respirator is compulsory to maintain provided to employees at

chemical process area and others line who handle the same job/ process.

b. Personal Protective Equipment (PPE) Management

- Cleaning

Respirator issued to staff shall be cleaned regularly.

Staff who maintain their own respirators should be trained in cleaning

procedures

Rough handling should be avoided as it may damage the respirator

- Storage

Respirators/ masks should be stored in a convenient location, away

from contaminated areas.

Respirators for emergency use should be maintained and stored,

ready for immediate use.

- Cartridges

Cartridges should be replaced on a regular basis, when an odor or

taste is perceived in the inhaled air or when the user experiences

discomforts.

- Maintenance

The employees should maintain the respirator use and wash their

faces and respirator face-pieces as necessary to prevent eye or skin

irritation associated with respirator use.

ii. Monitoring of exposure to Hazardous Chemical

a. The monitoring of exposure to employees for Manganese, Mercury, Cadmium,

Chromium and Lead during their work to be repeated and carries out every 6

month

b. The monitoring of exposure shall e conducted by hygiene technician.

c. Record the summary of the monitoring exposure shall be maintained in good

order and condition.

iii. Information, Instruction and Training

a. To continue providing the workers with information, instruction and training on

exposure to chemicals hazardous to health as may be necessary to enable them to

know the risk to health created by such exposure or miss handling and precautions

which should be taken

b. Without prejudice to the generality of the above, the information provided shall

include information on the result of the monitoring of exposure at workplace.

c. To display signage at working areas, where these contaminated were found high

d. To display type of PPE to be worn upon entering these area.

iv. Warning Sign at Manganese, Mercury, Cadmium, Chromium, and Lead and others

hazardous area

The employer shall ensure that the warning signs are posted at a conspicuous place at

every entrance to warn persons entering the area of the hazards.

v. Health surveillance programmed

The employer shall carryout a health surveillance programme especially for those expose

Manganese, Mercury, Cadmium, Chromium and Lead during their work.

3.0 Conclusion

This report has been divided into three main chapters whereby the first chapter is about the overview

of the plant. This chapter includes the company profile together with the organizational chart. It also

provides a brief description about the gas turbines and the generator.

The second chapter is about the mechanical system of the plant. There are 11 systems altogether and

each system is described briefly with the inclusion of pictures to give the reader a better view of the

system. Without these systems, the gas turbine will not function properly.

The second chapter is about the electrical system of the plant. Since the core business of the

organization is power production, there are various components that make up the electrical system. A

brief description is given about all the main components of the system together with relevant pictures.

4.0 Acknowledgement

I would like to extend his acknowledgement to the Trainee Supervisor, Encik Nasharuddin Bin

Ismail for his guidance and support. I would also like to thank the Port Dickson Power‟s Plant Manager,

Mr. Sankar MK Samy , Operations Manager Mr. Lukman Hakim Bin Ali and Maintenance Manager , Mr.

Wan Amran Wan Saupik during the author‟s Industrial Training at their power plant. I am indeed very

grateful for their guidance and encouragement during the 6 months and also for their valuable suggestions

as well as opinions made while undergoing the training. Besides that I would also like to thank all the

other Port Dickson Power‟s staffs for all their assistance and co-operation. Lastly, a special thanks to

Puan Rogayah Binti Othman that help me with all morale support and encouragement throughout my 6

months stint at the Port Dickson Power Berhad.