nt2-l3-g-gc_gn-69-00001_b

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/ PECC2

DOCUMENT STATUS : FOR REFERENCE

B 14-Jun-10 RE-ISSUED FOR REFERENCE SAARD O. KRIT K. SUMETH Y. A 10-May-10 ISSUED FOR REFERENCE SAARD O. KRIT K. SUMETH Y.

Rev. Date Description Prepd. Chkd. Appd.

Project :

Owner : Consultant:

EPC Contractor:

Consultant: Subcontractor :

Document Title : TRAINING MANUAL

WTP & WWTP MONITORING, MAINTENANCE & TROUBLESHOOTING

Project No : NT 2 Format : A4 Total Pages : 34

Designed by : Torishima Consortium Checked by :

Function Name Sign Date Function Name Sign Date

Approved Sumeth Y. 14-Jun-10 SM Checked Krit K. 14-Jun-10 LME Prepared Saard O. 14-Jun-10 QA/QC

Document No : NT2-L3-G-GC/GN-69-00001 Date:

14-Jun-10 Rev.

B

NHON TRACH 2 - 750MW COMBINED CYCLE POWER PLANT PROJECT

PETRO VIETNAM NHON TRACH 2 POWER JOINT STOCK COMPANY

FICHTNER GmbH & Co.KG CONNELL WAGNER (AURECON)

LILAMA PVC CONSORTIUM

TORISHIMA - AFCOLENCO - LILAMA 18 JSC.

TORISHIMA AF COLENCO-LILAMA 18 JSC 76 BUI THIXUAN,HAI BA TRUNG DISTRICT, Tel : 84-4-943 7880 HANOI, VIETNAM Fax : 84-4-943 7875/7876

Page B

TRAINING MANUAL FOR WTP & WWTP MONITORING,

MAINTENANCE & TROUBLESHOOTING

Rev. B : June 14, 2010

Torishima-AF Colenco-Lilama 18 JSC

Nhon Trach 2-750MW CCPP/ Lot 3 Balance of Plant


Page C

NHON TRACH 2 - WTP & WWTP TRAINING PROGRAM

1) OBJECTIVE :

TO LEARN HOW THE WTP & WWTP SYSTEM WORKS

TO LEARN HOW TO OPERATE THE WTP & WWTP SYSTEM

TO LEARN HOW TO TROUBLESHOOT & MAINTAIN THE WTP & WWTP SYSTEM

2) ATTENDEES:

No. Training Program Trainees Specialty Total Number

1

Water and Waste water treatment Operation and maintenance

- Mech. Engineer - Elec. and I&C Engineer

4


Page D

3) NHON TRACH 2 - WTP & WWTP TRAINING SCHEDULE (TENTATIVELY)

Venue: ORGANO ASIA SHAH ALAM OFFICE (MALAYSIA)

Day 1 4th July 2010

Arrival of Trainees at Kuala Lumpur, Malaysia & Hotel Check in.

Day 2 5th July 2010

Time Activity10:00a.m - 12:30p.m Introduction to Water Treatment System12:30p.m - 1:30p.m Lunch Break1:30p.m - 3:00p.m Cont Introduction to Water Treatment System3:00p.m - 3.15p.m Break 3:15p.m - 4.00p.m Q&A Session

Day 3 6th July 2010

Time Activity10:00a.m - 12:30p.m Introduction to Waste Water Treatment System12:30p.m - 1:30p.m Lunch Break1:30p.m - 3:00p.m Cont Introduction to Waste Water Treatment System 3:00p.m - 3.15p.m Break 3:15p.m - 4.00p.m Q&A Session

Day 4 7th July 2010

Time Activity10:00a.m - 12:30p.m Water Treatment Plant Operation through HMI Graphic Display 12:30p.m - 1:30p.m Lunch Break1:30p.m - 3:00p.m Cont Water Treatment Plant Operation through HMI Graphic Display3:00p.m - 3.15p.m Break 3:15p.m - 4.00p.m Q&A Session


Page E

Day 5 8th July 2010

Time Activity10:00a.m - 12:30p.m Waste Water Treatment Plant Operation through HMI Graphic Display12:30p.m - 1:30p.m Lunch Break1:30p.m - 3:00p.m Cont Waste Water Treatment Plant Operation through HMI Graphic

Display 3:00p.m - 3.15p.m Break 3:15p.m - 4.00p.m Q&A Session

Day 6 9th July 2010

Time Activity10:00a.m - 12:30p.m WTP & WWTP Monitoring, Maintenance & Troubleshooting 12:30p.m - 1:30p.m Lunch Break1:30p.m - 3:00p.m WTP & WWTP Monitoring, Maintenance & Troubleshooting 3:00p.m - 3.15p.m Break 3:15p.m - 3.30p.m Q&A Session3.45p.m 5.00p.m Test

Day 7 10th July 2010

Spare Day for Training

Day 8 11th July 2010

Hotel Check Out & Departure of Trainee from Kuala Lumpur, Malaysia.

Nhon Trach 2 CCPP Project

WTP & WWTP Plant

MAINTENANCE MANUAL

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MAINTENANCE MAINTENANCE of WATER of WATER

TREATMENT TREATMENT PLANTPLANT

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MONITORING AND MAINTENANCE MONITORING AND MAINTENANCE REQUIREMENTREQUIREMENT

Record the MB Regeneration step. If the MB Regeneration failed, the DM supply will stopDailyMB Regeneration Process

Apply hydraulic oil or grease into the motor gearbox when oil levelbelow the requirement level. Please refer to the individual equipmentmanual

MonthlyLubricant requirement (Blower)

Send the water sample to the laboratory for analysisMonthlySample analysis for water quality

Contact entire instrument supplier for calibration.AnnuallyCalibrate instruments

Observe chemical tank level daily. Replenish chemical when necessary.DailyChemical consumption

Observe for abnormal noise, vibration, surface temperature, andlubricant level if necessary. Ensure the operating condition such likeoperating flow rate and discharge pressure as per design.

Daily Rotating Equipment

Proper housekeeping and clean up the spillage. Daily System Area

Check the status and opening condition of equipment and instrumentsform control panel.

Visually check the PANEL display indication, local flow indicators andpressure indicators.

Acknowledge any alarm signals and take the appropriate correctiveaction. Operation personnel should confirm that the automatic operationis done correctly.

DailyControl Panel

Record down Daily Performance Log Sheet for Raw Water Treatment.DailyData collection

ProcedureCheckItem

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Monitoring & TroubleshootingMonitoring & Troubleshooting

Service Throughput ShortageService Throughput Shortage Poor Water QualityPoor Water Quality Individual Alarm in Alarm Page (SCADA Individual Alarm in Alarm Page (SCADA

System)System) Equipment Breakdown/Fault Equipment Breakdown/Fault

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Service Throughput ShortageService Throughput Shortage

Cycle of Service Time shorter Cycle of Service Time shorter Why ?Why ? System should be service ~ 24 Hours but only 20 Hours service , System should be service ~ 24 Hours but only 20 Hours service ,

system need regeneration ?system need regeneration ?

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Poor Water QualityPoor Water Quality

Conductivity & Silica still High after Regeneration Conductivity & Silica still High after Regeneration Why ?Why ?

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Rotating Equipment TroubleshootingRotating Equipment Troubleshooting

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Valve & Actuator TroubleshootingValve & Actuator Troubleshooting

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Valve & Actuator Troubleshooting Valve & Actuator Troubleshooting (Cont(Cont))

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Valve & Actuator Troubleshooting Valve & Actuator Troubleshooting (Cont(Cont))

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Conductivity & pH Sensor Conductivity & pH Sensor TroubleshootingTroubleshooting

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Conductivity & pH Sensor Conductivity & pH Sensor Troubleshooting (Cont)Troubleshooting (Cont)

General Maintenance Procedure for General Maintenance Procedure for SensorSensor

1. Clean1. Cleana) Rinse sensor in plain water a) Rinse sensor in plain water b) Use domestic cleaning agent to clean off coating depob) Use domestic cleaning agent to clean off coating deposits.sits.c) The electrode must be rinsed thoroughly with clean wac) The electrode must be rinsed thoroughly with clean water to avoid contamination of the ter to avoid contamination of the

calibration solution. calibration solution.

2. Check2. Checka) Check the sensor with standard solution.If reading isa) Check the sensor with standard solution.If reading is within the accuracy, sensor can be put within the accuracy, sensor can be put

back on line. Else proceed to calibration.back on line. Else proceed to calibration.

3. Calibration3. Calibrationa) Immersed clean electrodes in standard solution and lea) Immersed clean electrodes in standard solution and let it stabilize.t it stabilize.b) Adjust transmitter reading to the b) Adjust transmitter reading to the caluecalue of standard solutionof standard solution

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Switches TroubleshootingSwitches Troubleshooting

1.1. Valve Open /Close Limit SwitchValve Open /Close Limit Switch-- Make sure switches install at correct position Make sure switches install at correct position

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Switches Troubleshooting (Cont)Switches Troubleshooting (Cont)1.1. Level SwitchLevel Switch

-- Make sure switches working fine, if not replace new one.Make sure switches working fine, if not replace new one.-- Simulate level by adjusting the float /Rod sensor and monitor tSimulate level by adjusting the float /Rod sensor and monitor the he

simulate level in VDU.simulate level in VDU.

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PLC & I/O Module TroubleshootingPLC & I/O Module Troubleshooting

Allen Bradley Redundant System.Allen Bradley Redundant System.-- Redundant CPU, Network Module, Power Supply. Just Redundant CPU, Network Module, Power Supply. Just

replace the replace the faulty unit with stopping the system. faulty unit with stopping the system.

-- I/O Module hot swap.I/O Module hot swap.

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PLC & I/O Module PLC & I/O Module Troubleshooting (Cont)Troubleshooting (Cont)

How to troubleshoot the PLC & I/O ModuleHow to troubleshoot the PLC & I/O Module1. Using Individual PLC Module Indicator1. Using Individual PLC Module Indicator

-- CPU CPU

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Communication moduleCommunication module

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I/O ModuleI/O Module

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2. Using RS 5000 programming software2. Using RS 5000 programming software

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SILICA ANLAYZERSILICA ANLAYZER

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MMF MEDIA REPLACEMENTMMF MEDIA REPLACEMENT1. Temporary scaffold and platform should be prepared at top of the MMF for lifting

up and pouring the media. If permanent platform is not provided.

2. Filter media will be lifted up and poured into the MMF from the top manhole.

3. Fill in Gravel (1st, 2nd &3rd layer) via side manhole slowly and protect strainers from damage.

4. When 1 layer has been filled, make top surface level flat before filling next layer.

5. Close the side manhole after Gravel Layer and fill in Coarse Garnet, Fine Garnet, Silica, Sand and Anthracite accordingly.

6. Repeat Pressure Test after media charged and carrying leak checkespecially for Manhole.

7. Fill the water into MMF from the top until the water level is higher than the Anthracite soaking about 24 hours.

Note:When enter the vessel internal, oxygen shall be measured and shall be more than18%.

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RO TROUBLE SHOOTINGRO TROUBLE SHOOTING

1) Head Retaining Ring 1) Head Retaining Ring

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2) Head Assembly will not release from shell2) Head Assembly will not release from shell

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3) Seal Leakage3) Seal Leakage

i) Head Seal Leaki) Head Seal Leak

ii) Permeate Port Seal Leakii) Permeate Port Seal Leak

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4) Sudden Drop in Permeate Quality4) Sudden Drop in Permeate Quality

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MBE RESIN REPLACEMENTMBE RESIN REPLACEMENTResin replacement is recommended once per 2Resin replacement is recommended once per 2--3 years.3 years.1.1. Please note that information provided herewith is only basic guiPlease note that information provided herewith is only basic guideline for deline for

resin replacement, kindly consulting Organo Asia Sdn Bhd for detresin replacement, kindly consulting Organo Asia Sdn Bhd for detailed ailed procedures. procedures.

2.2. Mixed Bed resin withdrawal from Mixed Bed ExchangerMixed Bed resin withdrawal from Mixed Bed Exchangera)a) Remove all resins in the Mixed Bed Exchanger, supply Remove all resins in the Mixed Bed Exchanger, supply DeminDemin water water

to rinse out all remaining resins in the vessel.to rinse out all remaining resins in the vessel.b)b) Confirm the volume of each resin to be filled.Confirm the volume of each resin to be filled.

CationCation resin:250 litres resin:250 litres AmberjetAmberjet 1500 H 1500 H Anion resin: 700 litres Anion resin: 700 litres AmberliteAmberlite IRA402ClIRA402Cl

c)c) Fill up the Mixed Bed Exchanger with Fill up the Mixed Bed Exchanger with DeminDemin water until the water water until the water level reaches the middle of bottom sight glass.level reaches the middle of bottom sight glass.

d)d) Open top manhole and fill the cation resin.Open top manhole and fill the cation resin.e)e) Close the manhole.Close the manhole.f)f) Keep the cation resin one night for soaking. Rinse the resin.Keep the cation resin one night for soaking. Rinse the resin.g)g) Fill up the vessel by Fill up the vessel by DeminDemin water until middle of intermediate sight water until middle of intermediate sight

glass.glass.h)h) Open top manhole and fill the anion resin.Open top manhole and fill the anion resin.i)i) Close top manhole.Close top manhole.

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MAINTENANCE MAINTENANCE of WASTE of WASTE WATER WATER

TREATMENT TREATMENT PLANTPLANT

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MONITORING AND MAINTENANCE MONITORING AND MAINTENANCE REQUIREMENTREQUIREMENT

Carry out routine check of Water Treatment Plant System. Record Carry out routine check of Water Treatment Plant System. Record down Daily Performance Log Sheet for WTP System at least on down Daily Performance Log Sheet for WTP System at least on bihourly basis.bihourly basis.

If any abnormality of performance is found, quickly identify theIf any abnormality of performance is found, quickly identify the cause cause and rectify the problem.and rectify the problem.

Conduct pH sensor cleaning (with pure water and/or diluted Conduct pH sensor cleaning (with pure water and/or diluted HClHCl) and ) and calibration (with standard pH 4 and pH 7 buffer solution) at leacalibration (with standard pH 4 and pH 7 buffer solution) at least one a st one a week.week.

Schedule check for equipment as per recommended in itsSchedule check for equipment as per recommended in its individual individual INSTRUCTION MANUAL.INSTRUCTION MANUAL.

Schedule check for measuring instruments as per recommended in iSchedule check for measuring instruments as per recommended in itstsindividual INSTRUCTION MANUAL.individual INSTRUCTION MANUAL.

Conduct calibration of measuring instruments like suspended soliConduct calibration of measuring instruments like suspended solids ds meter, flowmeter and etc once a year if applicable.meter, flowmeter and etc once a year if applicable.

Periodically inspect of piece of equipment devices. Repair and/Periodically inspect of piece of equipment devices. Repair and/or or replace parts of piece of equipment immediately if abnormal sounreplace parts of piece of equipment immediately if abnormal sound, d, wear and tear is found. wear and tear is found.

Periodically check air tubing of pneumatic valves if possible. Periodically check air tubing of pneumatic valves if possible. If excess If excess air leak from tubing, that pneumatic valve may out of order for air leak from tubing, that pneumatic valve may out of order for openopen--close.close.

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MONITORING AND MAINTENANCE MONITORING AND MAINTENANCE REQUIREMENT (cont)REQUIREMENT (cont)

Apply hydraulic oil or grease into the motor gearbox when oil levelbelow the requirement level. Please refer to the individual equipmentmanual

MonthlyLubricant requirement

Send the water sample to the laboratory for analysisMonthlySample analysis for water quality

Contact entire instrument supplier for calibration.AnnuallyCalibrate instruments

Observe chemical tank level daily. Replenish chemical when necessary.DailyChemical consumption

Observe for abnormal noise, vibration, surface temperature, andlubricant level if necessary. Ensure the operating condition such likeoperating flow rate and discharge pressure as per design.

Daily Rotating Equipment

Proper housekeeping and clean up the spillage. Daily System Area

Check the status and opening condition of equipment and instrumentsform control panel.

Visually check the PANEL display indication, local flow indicators andpressure indicators.

Acknowledge any alarm signals and take the appropriate correctiveaction. Operation personnel should confirm that the automatic operationis done correctly.

DailyControl Panel

Record down Daily Performance Log Sheet for Raw Water Treatment.DailyData collection

ProcedureCheckItem

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nt2-l3-g-gc_gn-69-00001_b

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