8/17/2016

Training Record Book

Technical & Commercial
Duration: 1 Week

Guidelines:
The checklist below is not an exhaustive description of jobs carried out in the work area. In case of any activity not listed in this document, please describe the same for proper records.

Date Signature
Heat Rate Calculations. 4/11/2016 SAQLAIN RAZA

Sources of Heat Loss at HUB Power Station. 8/11/2016 SAQLAIN RAZA

Legend:
Equipment Condition Monitoring Techniques. 31/10/2016 SAQLAIN RAZA Understanding: Working Principle of Machine; Knowledge about Tools, Jigs and
fixtures, Applicable Software Packages.
Rotating Equipment vibration Analysis. 31/10/2016 SAQLAIN RAZA
Self Study

Safety Rules: Potential Hazards; Required PPE; Precautions.

Power Purchase Agreement (PPA). 2/11/2106 SAQLAIN RAZA Operations: Required Skill Level; Job Steps, Sequence and Duration; Crew
Composition, List of Applicable QA / QC.
Fuel Supply Agreement (FSA). 3/11/2016 SAQLAIN RAZA Observation: Visual Witnessing of operation, Clarification / Discussion with Supervisor /
Selected Technical Reports. 1/11/2016 SAQLAIN RAZA Seniors.

Understanding Safety Rules Operations Observation Date Signature

Operational Performance And Losses (OPAL)
8/11/2016 SAQLAIN RAZA
Calculations.

Monthly Billing. 4/11/2016 SAQLAIN RAZA

Equilent Weighted Forced Outage and Partial Derating -

4/11/2016 SAQLAIN RAZA
Issues/implications.

Field Measurment of Rotating Equipment vibration. 31/10/2016 SAQLAIN RAZA

Field / Major Activities

Infrared Thermography. 3/11/2016 SAQLAIN RAZA

Valve Drain Survey. 3/11/2016 SAQLAIN RAZA

Measurement of Excess Oxygen in Flue Gas. 1/11/2016 SAQLAIN RAZA

Ultra Sonic Flow Measurement. 1/11/2016 SAQLAIN RAZA

Helium survey For Condenser Vacum Leakage. 2/11/2016 SAQLAIN RAZA

RFO Level Measurement by Ullage Tape. 2/11/2016 SAQLAIN RAZA

Cold Draft Test. 1/11/2016 SAQLAIN RAZA

System Integrity Check. 4/11/2016 SAQLAIN RAZA

Fuel Management. 3/11/2016 SAQLAIN RAZA

Plant Operatins, Reliability and Availablity data Capturing,
31/10/2016 SAQLAIN RAZA
Monitoring Analysis and Archival.

Understanding Safety Rules Operations Observation Date Signature

Vibration Analyzer. 31/10/2016 SAQLAIN RAZA
Tools, Plant & Equipment

IR Thermal Camera. 1/11/2016 SAQLAIN RAZA

Ultrasonic Flow Meter. 1/11/2016 SAQLAIN RAZA

Ultrasonic Leak Detector. 1/11/2016 SAQLAIN RAZA

Ullage Tape. 2/11/2016 SAQLAIN RAZA

Understanding
Safety Rules Operations Observation
Date Signature
IR Thermography Report. 1/11/2016 SAQLAIN RAZA

Vibration Analysis Report. 1/11/2016 SAQLAIN RAZA
QA / QC

Selected Reports and Formats. 2/11/2016 SAQLAIN RAZA

Understanding Safety Rules Operations Observation Date Signature

Workfow

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Understanding Safety Rules Operations Observation Date Signature
Others

Area Section
Technical & Commercial Training Notes - Key Learnings Vibration Analysis
To be flled by Trainee

Technical & Commercial department performs the condition monitoring of the equipment in order to ensure their health and performance. This department makes sure that

the equipment is running on it's maximum efficiency. The detection of any fault in the machine before it's failure is one of the most important function performed. In addition

to this, T&C department is also responsible for generating the bills for the units of electricity supplied to WAPDA.

As mentioned earlier, condition monitoring is one of the prime functions performed by T&C department. There are 4 major techniques for CM, which are defined below:

1. IR Thermography: IR (Infrared) thermography can be defined as the process of generating visual images that represent variations in IR radiance of surface of objects. Any

object with a temp greater that absolute zero emits infrared radiations proportional to their temperature. An infrared thermometer or infrared camera, can be used to check
To be flled by
this infrared temperature and determine any fault. An infrared thermometer will only indicate the temperature of a certain point whereas an infrared camera will also show a

picture representing different temperature zones.

At HUB plant, T&C department uses both infrared thermometer that is shown on the right (SKF CMSS 3000-SL) and infrared camera.

The infrared camera is owned by electrical department and is landed to T&C department on request. This infrared camera will

store the image in the storage card and can be transferred to the computer using a software which will indicate the temperature

at various zones. The area which is colored red, is usually a faulty zone.

2. Vibration Analysis: Vibration can be defined as the periodic motion of the particles of an elastic body or medium in alternatively opposite directions from the position of

equilibrium when the equilibrium has been disturbed. Every moving machine will have vibrations of different magnitudes and frequencies. These vibrations can be assessed

to determine the faults in the machinery. The magnitude of vibration is expressed as:

a. Displacement

b. Velocity

c. Acceleration

Human touch is not sensitive enough to discriminate between different levels of vibrations. Therefore, vibration analyzers are available which consist of various transducers

that will sense and provide an electrical output reflective of the vibrational displacement, velocity or acceleration. Amplitude vs Time (Waveform) is generated for these

vibrations which with the help of FFT (Fast Fourier Transformation) is converted into Amplitude vs Frequency (Spectrum) graph. This spectrum is unique for different faults

and can be used for diagnosis.

At HUB plant, vibration analysis is done using SKF CMVA65 Micro Log instrument which has a magnetic probe.

This probe is placed in axial, vertical and horizontal directions to determine the exact vibration values. The probe

must be settled at the point. The values obtained are stored in the instrument and then it is transferred to the

computer using machine analyst software. By using this software, recent values can be compared with the past

values and spectrum can also be obtained. These values and spectrum can be used for further analyses and

diagnosing the actual issue.

3. Oil Analysis: One of the oldest technique still used is oil analysis. It can be used to define three basic conditions related to the machine's lubrication or lubrication system.

a. Condition of the oil i.e. will it's current condition lubricate as per design. Testing is performed to determine lubricant viscosity, acidity etc., as well as other chemical

analysis to quantify the condition of oil additives like corrosion inhibitors etc.

b. Lubrication system condition i.e. have any physical boundaries been violated causing lubricant contamination, by testing for water content, silicon and other contaminants.

c. Machine condition itself by analyzing wear particles existing in the lubricant, machine wear can be evaluated and quantified.

4. Ultrasonic Analysis: Ultrasounds are defined as sound waves having frequency greater than 20 kHz. Many rotating equipment and many fluid system conditions will emit

sound patterns in the ultrasonic frequency spectrum. Changes in these ultrasonic wave spectrum are reflective of the equipment condition. Ultrasonic signature analysis can

be used to identify problems related to component wear as well as fluid leaks, vacuum leaks and steam trap failures.

Valve Drain Survey: This survey is actually done on regular basis to determine the leakage or passing from a valve. This activity is quite important because the leakage from

a closed valve will lead to loss of energy and result in decrease of plant efficiency. This job is performed using the SKF Infrared Thermometer CMSS 3000-SL. This thermometer

will indicate the increased temperature in the region where the valve would be passing. Check sheet for the inspection is developed for all valves.

Using IR temperature gun, we checked the blowdown valve of HP turbine, that goes into the condenser whether it is passing or not. This valve is opened when the unit is shut

down and steam from turbine has to be drained to the condenser. The temperature at unit 2 blowdown valve was found to be 97'C, at unit 3 it was found to be 44'C and at unit

4 it was found to be 111'C. The temperature readings showed that the blowdown valve at unit 4 was defected.

Similarly, recirculation valve of feed water pump was also checked using IR temperature gun. Recirculation valve is motor operated and is closed when the unit is at full load.

Temperature was checked at 3 points that were before valve, on the body of valve, and after valve. Temperatures were recorded at recirculation valve of unit 2, 3 and 4. High

temperature was found at the recirculation valve of Unit 3, FWP-B.

Excess Oxygen in Flue Gas: This test is performed in the GAH (Gas Air Heater) to determine the leakage of air (oxygen) inducted using FD fan. The leakage of oxygen form fresh air

to flue gases on other side of GAH is the loss of energy as the A/F ratio will decrease due to this. In addition to oxygen concentration in flue gas, concentration of carbon dioxide

and carbon monoxide are also determined.

Ultrasonic Flow Measurement: An ultrasonic flow meter measures the velocity of a fluid with ultrasound to calculate volume

flow. Using ultrasonic transducers, the flow meter can measure the average velocity along the path of an emitted beam of

ultrasound, by averaging the difference in measured transit time between the pulses of ultrasound propagating into and

against the direction of flow or by measuring the frequency shift from Doppler's effect.

Ultrasonic flow meter consists of two contact probes and a display panel on which the readings are displayed of flow rate (m3/hr.). Instrument used is EESIFLO 3000. The

probes are placed using a contact gel. The probes are then locked and secured with arrows marked in outward direction. The distance between the probes is determined using

instrument when the thickness and diameter of pipe are entered. When the flow is started, the instrument will represent the flow on the screen.

Helium Survey: This survey is conducted to determine the condenser vacuum leakage. If the air would ingress in the condenser, the

pressure inside the condenser would rise. Consequently the temperature inside the condenser would rise as well. This would be

considered as the loss of energy because the steam in turbine will not expand to the least pressure due to rise of pressure in

condenser. To check for this leakage, helium gas is used as it is lighter than air and can be easily detected.
 Helium is sprayed at various points such as I&C joints, manholes etc. If their would be any leakage then helium would be detected

through the instrument shown on the right which is placed at the steam ejector. The instrument used is PHD-4 leak detector

manufactured by Agilent Technologies.

RFO Level Measurement: Level measurement of the RFO tank is done using the level gauge, connected to each RFO tank but the reading obtained through this gauge is counter

checked using ullage tape.

We performed the level measurement of RFO tank-4 using ullage tape. Initially take-5 was done in which the hazards that may be

present were detected. These hazards included slippage, tipping, attack by bees etc. Mitigation measures were taken for these

hazards that were to keep the foot firmly on the stairs, keep a safe distance from the other person, keep your face away when the

cap is opened to prevent interaction with fumes etc. After that, ullage tape was unlocked and was unrolled. The point where the tape

came in contact with RFO, an alarming sound was heard. The reading was taken and was found to be 3.017m. This was the reading of the empty tank. The total height of the

RFO tank is 21m. If we subtract the obtained reading from total height, then this will give the level of oil in the tank that was 17.983m.

Cold Draft Test: This test is the initial step when any unit is in RTS (Return To Service) condition after the outage. This test is performed on the air path. In this test, FD fan is

checked at various positions of I.G.Vs (Inlet Guide Vanes) to check that the proper flow of air is obtained. Flow, temperature and pressure of air is obtained at various

positions along the air flow path and these values are checked with the previously obtained values.

Fuel Management: According to FSA (Fuel Supply Agreement), PSO is bound to supply RFO to

HUBCO for production of electricity. PSO has made an agreement with APL (Asia Petroleum

Limited) to supply oil from ZOT (Zulfiqarabad Oil Terminal) to HUB plant. For this purpose,

APL is using a 78km, 14" pipeline that has a transfer capacity of 7389 tons. APL has 5 RFO

tanks at ZOT each having a capacity of 32000 tons whereas at HUB plant, there are 4 RFO tanks

each having capacity of 30000 tons and a height of 21m in which oil is filled up to 19m.

WAPDA sends it's electricity demand on yearly, quarterly and monthly basis. On the basis of

this demand, HPSL calculates oil demand. As a rule of thumb, 232 tons of RFO is required to

generate 1 GW of electricity. HPSL has to maintain 60% of RFO in it's tank for all time. After

RFO is received by HPSL, it's price is charged from WAPDA on the basis of international price

of RFO which is received in 14 days and this money is then transferred to PSO within 14 days,

Billing: Bill against total units consumed by WAPDA is prepared on daily basis by obtaining generation data from operations department and after calculation of RFO

consumed in this generation. All the values of MWH generation is collected from mid-night report that is prepared by control room on daily basis. The readings are then sent

to HUBCO head office, which is then communicated to WAPDA as an invoice. The payment is released on monthly basis and also includes FADL deduction.

FADL (Failure to Achieve Dispatch Level) is the penalty that has to be paid if HUB power fails to generate electricity within agreed tolerance band of power generation. This

money is deducted monthly by WAPDA. If the demand of electricity by WAPDA is less that 1130 MW, then this tolerance band is 6% and if the demand of electricity form

WAPDA is greater than 1130 MW, then this tolerance band is 4%.

PLAC (Partial Load Adjustment Charges) is the penalty paid by either WAPDA or HUBCO. If WAPDA consumes less electricity, than it has demanded then this will cause the

efficiency of the station to decrease and in return more RFO will be consumed. In this case, WAPDA will pay PLAC. If HUBCO is unable to meet the demand of WAPDA

continuously for 12 hours keeping itself in tolerance band, then HUBCO will have to pay PLAC. If electricity generated goes out of tolerance band and stays out of it, continuously

for 12 hours then FADL is converted to PLAC and is payable by HUBCO.

FO + PLAC 960 GWH: This is the condition imposed by WAPDA in PPA (Power Purchase Agreement). Both FO (Forced Outage) and PLAC are variable and depends on the factor

provided by WAPDA on monthly basis. It not only depends on month but also depends on hours as peak hours and non-peak hours. To calculate FO or PLAC,

multiply the month factor provided by WAPDA with the number of hours and the MW of electricity shortfall. IF the sum of FO and PLAC is greater than 960 GWH after the year

checked from April to next year's March, then a penalty has to be given by HUBCO to WAPDA.
Manager Review

Saqlain has completed all the tasks assigned to him during his tenure in the T&C department. He needs to complete his training regarding helium survey and excess oxygen measurement in the buffer week. I wish him
all the best in his future training.
 `

Trainee Supervisor Section Head

Signatures SAQLAIN RAZA M Usama Malik

Date 4/11/2016 7/11/2016