Generators 5t534i

ARAMIS Development Ltd

Vendor Document No.

Rev.

Page

TPC-DQR-002-TRM-MNT-301

A

1 of 54

TRAINING MODULE

MAINTENANCE MODULES ELECTRICAL GENERATORS

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY (DQR) PROJECT DUNG QUAT, VIETNAM

Requisition Number:

8474L-000-CFB-XXXX-0001

Purchase Order Number:

8474L-000-CS01-17061

Equipment / Item Tag:

Not Applicable

Equipment/Item Description:

Not Applicable

TPC Document Number:

8474L-000-A5016-0000-001-301

Document Class:

X

Stamp

Comment given in this document does not relieve vendor of his/her responsibility for the correct engineering design and fabrication. This equipment or product shall be made as per the codes, requisition, specification, project procedures, and international standards.

A

12-OCT-07

Issue for review

JS

Paul Walsh

JB Guillemin

Rev

Date

Status

Written By (name & visa)

Check By (name & visa)

Approved By (name & visa)

Pages changed in this Revision: Sections changed in last revision are identified by a vertical line in the margin DOCUMENT REVISIONS

Page 1 of 54

TRAINING MODULE GENERATORS

8474L-000-A5016-0000-001-301 REV: A DATE: 12/10/07

TRAINING MODULE


A

12/10/07

JS

Paul Walsh

JB Guillemin

REV

DATE

PREPARED BY

CHECKED BY

APPROVED BY

TRAINING DURATION

VENUE

ATTENDANCE ATTENDEES REQUIREMENTS MODULE OBJECTIVES

INSTRUCTORS NAME/POSITION SUMMARY/AGENDA

Page 2 of 54


8474L-000-A5016-0000-001-301 REV: A DATE: 12/10/07

IMPORTANT

THIS TRAINING MODULE HAS BEEN PREPARED BY ARAMIS FOR THE DUNG QUAT REFINERY. THIS MODULE MUST BE RECOGNIZED AS A TOOL AND GUIDE ONLY. IT WOULD BE IMPOSSIBLE TO ANTICIPATE AND PRESENT ALL POTENTIAL VARIABLES AND PROCESS CONDITIONS THAT OPERATIONAL PERSONNEL MIGHT BE EXPOSED TO. IT IS IMPERATIVE THAT THE READER ALWAYS AS CERTAIN THAT REFERENCE MATERIALS UTILIZED, WHILE PERFORMING OPERATIONAL DUTIES, CONFORM AT A MINIMUM TO THE LATEST ISSUE OF STANDARD OPERATING PROCEDURES, SAFETY CODES, ENGINEERING STANDARDS, AND GOVERNMENT REGULATIONS. SOME DESIGN FIGURES MIGHT NOT BE IN LINE DURING THE START-UP OF THE REFINERY.

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8474L-000-A5016-0000-001-301 REV: A DATE: 12/10/07

TABLE OF CONTENT

PART 1: ELECTRICAL GENERATOR TYPES....................................................................... 7 PART 2: STEAM TURBINE & DIESEL ENGINE GENERATOR……..………...…….………...13

SECTION 1 : ELECTRIC GENERATOR Identification......................................................... 17 1.1.

Location in the Plant................................................................................. 20

1.2.

Location in the Proces.............................................................................. 21

1.3.

Criticality................................................................................................... 21

SECTION 2 : SPECIFICATION AND ARRANGEMENT ........................................................ 23 2.1.

Model and Technical Specification ........................................................... 23

2.2.

General Layout......................................................................................... 24

SECTION 3 : ELECTRIC GENERATOR OPERATION........................................................ 27 3.1.

Normal Operation ..................................................................................... 27

3.2.

Start up Procedure ................................................................................... 27

3.3.

Shutdown Procedure................................................................................ 27

SECTION 4 : ELECTRIC GENERATOR MAINTENANCE................................................... 32 4.1.

Maintenance Procedure ........................................................................... 32

4.2.

Preventive Maintenance........................................................................... 32

4.3.

On Condition Maintenance ....................................................................... 34

4.4.

Inspection Requirement ........................................................................... 34

SECTION 5 : ELECTRIC GENERATOR TEST & CALIBRATION ....................................... 36 5.1.

Static Test ................................................................................................ 37

5.2.

Dynamic Test ........................................................................................... 37

5.3.

Calibration ................................................................................................ 37

SECTION 6 : DIAGNOSTIC & TROUBLESHOOTING .......................................................... 39 6.1.

Troubleshooting Diagram ......................................................................... 39

SECTION 7 : SPARE PARTS AND CONSUMABLE ............................................................. 41 7.1.

OEM/ Generic Spare Part List .................................................................. 41

7.2.

Consumable ............................................................................................. 41

SECTION 8 : SPECIAL TOOLS............................................................................................. 43 8.1.

List of Special Tools ................................................................................. 43

8.2.

Maintenance, Calibration, Certification, Storage of Special Tools ............ 43 Page 4 of 54


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PART 3: HSE……………………………………………………………………..…………………. 45 PART 4: REFERENCE DOCUMENTS INDEX……………….……………..…………..………. 46 PART 5: GLOSSARY/ ACRONYM…………………………….……………..…………..………. 49 Annex 1: Instructor Presentation Material .............................................................................. 50 Annex 2: Instructor Assessment Material............................................................................... 51

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8474L-000-A5016-0000-001-301 REV: A DATE: 12/10/07

TRAINING MODULE

MAINTENANCE MODULES ELECTRICAL GENERATORS Course Content:

Part 1 - ELECTRIC GENERATOR TYPES Part 2 Section 1 -

X

STEAM TURBINE & DIESEL ENGINE GENERATOR ELECTRIC GENERATOR IDENTIFICATION

Section 2 - SPECIFICATION AND ARRANGEMENT Section 3 -

ELECTRIC GENERATOR OPERATION

Section 4-

ELECTRIC GENERATOR MAINTENANCE

Section 5 -

ELECTRIC GENERATOR TEST & CALIBRATION

Section 6 - DIAGNOSTIC & TROUBLESHOOTING Section 7 - SPARE PARTS AND CONSUMABLE Section 8 - SPECIAL TOOLS Part 3 - HSE Part 4 - REFERENCE DOCUMENTS INDEX Part 5 – GLOSSARY/ ACRONYM

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PART 1: ELECTRIC GENERATOR TYPES AN ELECTRICAL GENERATOR IS A DEVICE THAT CONVERTS KINETIC ENERGY TO ELECTRICAL ENERGY, GENERALLY USING ELECTROMAGNETIC INDUCTION. THE REVERSE CONVERSION OF ELECTRICAL ENERGY INTO MECHANICAL ENERGY IS DONE BY A MOTOR, AND MOTORS AND GENERATORS HAVE MANY SIMILARITIES. In this refinery plant we are using two types of Electric Generators, such as: a. 4 Unit x 27 MW of Steam Turbine Generator (STG), as a main supply power for the plant, and b. 1 unit x 1.6 MW of Diesel Engine Generator, as an emergency generator. Apart from producing electric power for the plant, that STG also deliver High Pressure Steam, Medium and Low Pressure Steam in to the refinery plant for various needed of operations. In normal operation condition, electrical power generated by 3 unit of STG, which maximum 81MW, its more than sufficient for all electricity of refinery plant requirements. Than 1 unit will be standby as a spare.

Shin Nippon Condensing Multistage Steam Turbine

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1.1.

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Synchronous Generators

3 PHAES SYNCHRONOUS GENERATOR This work begins with an introduction to energy resources and the main electric energy conversion solutions, along with efficiency and environmental merits and demerits. The classification and principles of various electric generator topologies are covered alongside their power ratings and main applications including constant-speed synchronous generators, variable-speed wound rotor induction generators, cage rotor induction generators, claw pole rotor, induction, permanent magnet-assisted synchronous, switched reluctance generators, permanent magnet synchronous generators (PMSGs), transverse flux and flux reversal PMSGs, and linear motion permanent magnet alternators. Next come the main prime movers for electrical generators from topologies to basic performance equations and practical dynamic models and transfer functions

Synchronous Generator Operation

In practice, permanent magnet synchronous generators are not used very much. There are several reasons for this. One reason is that permanent magnets tend to become demagnetized by working in the powerful magnetic fields inside a generator. Another reason is that powerful magnets (made of rare earth metals, e.g. Neodymium) are quite expensive, even if prices have dropped lately. 1.2.

AC EXITER

A generator that uses field coils instead of permanent magnets requires a current flow to be present in the field coils for the generator to be able to produce any power at all. If the field coils are not powered, the rotor can spin without the generator producing any usable electrical energy. Page 8 of 54


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For older and very large power generating equipment, it has been traditionally necessary for a small separate exciter generator to be operated in conjunction with the main power generator. This is a small permanent-magnet generator which produces the constant current flow necessary for the larger generator to function. Most modern generators with field coils feature a capability known as self-excitation where some of the power output from the rotor is diverted to power the field coils. Additionally the rotor or stator contains a small amount of magnetizable metal, which retains a very weak residual magnetism when the generator is turned off. The generator is turned on with no load connected, and the initial weak field creates a weak flow in the field coils, which in turn begins to slightly affect the rotor to begin to produce current that then further strengthens the field. This loop continues to increase field voltage and output power until the generator reaches its full operating output level. This initial self-excitation process does not work if the generator is started connected to a load, as the load will quickly dissipate the slight power production of the initial field buildup process. It is additionally possible for a self-exciting generator either turned off or started with a load connected to result in dissipation of the residual magnetic field, resulting in complete nonfunction of the generator. In the case of a 220v portable generator commonly used by consumers and construction contractors, this loss of the residual field can usually be remedied by shutting down the generator, disconnecting all loads, and connecting what are normally the high-voltage/amperage generator outputs to the terminals of a common 9-volt battery. This very small current flow from the battery (in comparison with normal generator output) is enough to restore the residual self-exciting magnetic field. Usually only a moment of current flow, just briefly touching across the battery terminals, is enough to restore the field. 1.3.

Permanent Magnet Generator

The generator moves an electric current, but does not create electric charge, which is already present in the conductive wire of its windings. It is somewhat analogous to a water pump, which creates a flow of water but does not create the water inside. Other types of electrical generators exist, based on other electrical phenomena such as piezoelectricity, and magneto hydrodynamics. The construction of a dynamo is similar to that of an electric motor, and all common types of dynamos could work as motors.

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Piezoelectricity is the ability of some materials (notably crystals and certain ceramics) to generate an electric potential[1] in response to applied mechanical stress. This may take the form of a separation of electric charge across the crystal lattice. If the material is not shortcircuited, the applied charge induces a voltage across the material. The piezoelectric effect is reversible in that materials exhibiting the direct piezoelectric effect (the production of electricity when stress is applied) also exhibit the converse piezoelectric effect (the production of stress and/or strain when an electric field is applied). For example, lead zircon ate titan ate crystals will exhibit a maximum shape change of about 0.1% of the original dimension. The effect finds useful applications such as the production and detection of sound, generation of high voltages, electronic frequency generation, microbalances, and ultra fine focusing of optical assemblies. Magneto hydrodynamics (MHD) (magneto-fluid-dynamics or hydro-magnetic) is the academic discipline which studies the dynamics of electrically conducting fluids. Examples of such fluids include plasmas, liquid metals, and salt water. The word magneto hydrodynamics (MHD) is derived from magneto- meaning magnetic field, and hydro- meaning liquid, and dynamics meaning movement.

1.4.

Load Sharing s

Load Sharing Facility (or simply LSF) is a commercial computer software job scheduler sold by Platform Computing. It can be used to execute batch jobs on networked UNIX and Windows systems on much different architecture. Load sharing - configuring more than one system to perform the same function so that the workload is shared between them. A job scheduler is an enterprise software application that is in charge of unattended background executions, commonly known for historical reasons as batch processing. They may also be known as Distributed Resource Management Systems (DRMS) or Distributed Resource Managers (DRM). Today's job schedulers typically provide a graphical interface and a single point of control for definition and monitoring of background executions in a distributed network of computers. Increasingly job schedulers are required to orchestrate the integration of real-time business activities with traditional background IT processing, across different operating system platforms and business application environments. There are many concepts that are central to almost every job scheduler implementation and that are widely recognized with minimal variations: Page 10 of 54


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Jobs, Dependencies, Job Streams and s. The Job Scheduling software is installed on a single machine (Master) while on production machines only a very small component (Agent) is installed that awaits commands from the Master, executes them, and returns the exit code back to the Master. Various schemes are used to decide which particular job to run. Parameters that might be considered include: Job priority, Compute resource availability, License key if job is using licensed software, Execution time allocated to , Number of simultaneous jobs allowed for a , Estimated execution time, Elapsed execution time, Availability of peripheral devices, Occurrence of prescribed events Device Management is a set of technologies, protocols and standards used to allow the remote management of mobile devices, often involving updates of firmware over the air (FOTA). The network operator, handset OEM or in some cases even the end (usually via a web portal) can use Device Management, also known as Mobile Device Management, or MDM, to update the handset firmware/OS, install applications and fix bugs, all over the air. [1]

. Thus, large numbers of devices can be managed with single commands and the end is freed from the requirement to take the phone to a shop or service center to re-flash or update. 1.5.

Generator Control

An electric switchboard is a device that directs electricity from one source to another. It is an assembly of s, each of which contains switches that allow electricity to be redirected. The operator is protected from electrocution by safety switches and fuses. There can also be controls for the supply of electricity to the switchboard, coming from a generator or bank of electrical generators, especially frequency control of AC power and load sharing controls, plus gauges showing frequency and perhaps a synchronscope. The amount of power going into a switchboard must always equal to the power going out to the loads. Inside the switchboard there is a bank of bus bars - generally wide strips of copper to which the switchgear is connected. These act to allow the flow of large currents through the switchboard, and are generally bare and not insulated. Power to a switchboard should first be isolated before a switchboard is opened for maintenance, as the bare of busbars represent a severe electrocution hazard. Working on a live switchboard is rarely necessary, and if it is done then precautions should be taken, such as standing on a thick rubber mat, the use of gloves etc. Page 11 of 54


8474L-000-A5016-0000-001-301 REV: A DATE: 12/10/07

TRAINING MODULE


Course Content:


STEAM TURBINE & DIESEL ENGINE GENERATOR

X

ELECTRIC GENERATOR IDENTIFICATION



Section 4-


Section 5 -


Section 6 - DIAGNOSTIC & TROUBLESHOOTING Section 7 - SPARE PARTS AND CONSUMABLE Section 8 - SPECIAL TOOLS Part 3 - HSE Part 4 - REFERENCE DOCUMENTS INDEX Part 5 - GLOSSARY/ ACRONYM

PART 2: STEAM TURBINE & DIESEL ENGINE GENERATOR Page 12 of 54


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There are two kinds of generator using in this refinery plant. 1. Four (4) unit of 27MW Steam Turbine Generator and, 2. One (1) unit of 1.6 MW Diesel Engine Generator for Emergency Power Supply. 2.1. STEAM TURBINE GENERATOR A Steam turbine is a mechanical device that extracts thermal energy from pressurized steam, and converts it into useful mechanical work. The steam turbine is a form of heat engine that derives much of its improvement in thermodynamic efficiency from the use of multiple stages in the expansion of the steam, as opposed to the one stage in the Watt engine, which results in a closer approach to the ideal reversible process. In general, types of steam turbines include condensing/ noncondensing, reheat, extraction and induction: Non condensing or backpressure turbines are most widely used for process steam applications. The exhaust pressure is controlled by a regulating valve to suit the needs of the process steam pressure. Condensing turbines are most commonly found in electrical power plants, especially nuclear plants. These turbines exhaust steam in a partially condensed state, typically of a quality near 90%, at a pressure well below atmospheric to a condenser. These turbines are somewhat rare in the power industry because the condensing water in the last turbine stages requires more expensive materials; otherwise corrosion of the blades becomes a major problem. They are, however, very common in the nuclear power sector for various reasons. Reheat turbines are also used almost exclusively in electrical power plants. In a reheat turbine, steam flow exits from a high pressure section of the turbine and is returned to the boiler where additional superheat is added. The steam then goes back into an intermediate pressure section of the turbine and continues its expansion. Extracting turbines are common in many applications, particularly in certain manufacturing sectors such as papermaking which require steam at a certain pressure and temperature. In an extracting turbine, steam is taken from a point of the turbine having the desired temperature and pressure, and used for industrial process needs or sent to boiler feed water heaters. Adding boiler feed water heaters is done to improve overall cycle Page 13 of 54


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efficiency. Extraction flows may be controlled with a valve, or left uncontrolled. A one-way valve is always located on the extraction piping. In the event of an emergency turbine shutdown, pressure from the extraction line can spin the turbine backwards if not checked with such a one-way valve. Cruising turbines were used in US Navy designs of the 1950s and 60s. These turbines had staging which was designed for slow and medium speeds, with additional stages upstream which were only used for high speed operations. In normal cruising operation the upstream impulse stages were byed. Reversing Turbines are equipped with one or more stages of blades that are faced in the opposite direction of the main blading. A valving arrangement allows for the main steam line to be closed to the forward blades and opened to the reversing blade elements. These reversing blades are mounted on the same shaft as the forward elements. Normally the reversing blades share the same condenser. During reversing operations, the forward blade elements are spinning backwards in hot steam. This incurs a large efficiency loss known as wind age loss. This steam is relatively stagnant and the forward blades may overheat during extended operation. Reversing steam turbines were once common in the marine industry, although their use has declined with the rise of the diesel engine. Induction turbines introduce low pressure steam at an intermediate stage to produce additional power. 2.2. DIESEL ENGINE GENERATOR A diesel generator is the combination of a diesel engine with an electrical generator (often called an alternator) to generate electric energy. Diesel generators are used in places without connection to the power grid or as emergency power-supply if the grid fails. These generators are widely used not only for emergency power, but also many have a secondary function for providing back up power to utility grids. The Diesel engine is an internal combustion engine which operates using the Diesel cycle named after German engineer Rudolf Diesel, who invented it in 1892, based on the hot bulb engine, and for which he received a patent on February 23, 1893. The Diesel cycle uses compression ignition: the fuel ignites upon being injected into the highly compressed air in the combustion chamber. By contrast, petrol engines utilize the Otto cycle in which fuel and Page 14 of 54


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air are typically mixed before entering the combustion chamber, the mixture then being ignited by a spark plug. Compression ignition is generally considered undesirable in Otto cycle engines The internal combustion engine is an engine in which the combustion of fuel and an oxidizer (typically air) occurs in a confined space called a combustion chamber. This exothermic reaction creates gases at high temperature and pressure, which are permitted to expand. The defining feature of an internal combustion engine is that useful work is performed by the expanding hot gases acting directly to cause movement of solid parts of the engine, by acting on pistons, rotors, or even by pressing on and moving the entire engine itself.

This contrasts with external combustion engines, such as steam engines and Stirring engines, which use an external combustion chamber to heat a separate working fluid, which then in turn does work, for example by moving a piston or a turbine.

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Course Content:



X



Section 4-


Section 5 -



SECTION 1: ELECTRIC GENERATOR IDENTIFICATION

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The 4 Unit Steam Turbine Generator is known as tag numbers: A-4001A, A-4001B, A-4001C and A-4001 D. The Diesel Engine Generator is A-4008. The objective for the power generation system is to provide refinery plant with different modes of operation of following: a. Electric Power b. High, Medium and Low Pressure Steam. Maximum power installed in the plant is 4 x 27MW. For normal operation the power plant is required for 81MW, generated by 3 x 27MW STGs normally operating. And plus 1 generator 27MW standby as spare. The turbines are Medium Pressure (MP) Steam extraction and condensation type. In normal operating mode, three turbine sets are able to meet the demand for MP Steam. Steam capacity of boilers is 4 x 196 T/h at 107kg/Cm²g and 505⁰C. In normal refinery operation three boilers will operate at reduce capacity. In case one of the three operating boilers trips, the other two boilers are required to quick ramp-up to their MCR capacity. HHP, HP (letdown from HHP within power station), MP and LP steam system are designed to meet the steam demands for all modes of refinery operation. Pressure reducing/ desuperheating stations are installed to ensure reliable supply of steam to the refinery at all pressure levels in various operating conditions. Diesel Engine Generator A-4008 (Emergency Generator) is designed to generate power of 1.2MW to provide an emergency power supply during Emergency Shutdown of the refinery to emergency lighting, instrumentation/ control UPS battery charging, switchgear trip/ close DC supply equipment. The power generation system consists of following equipments: 1.1.

Steam Boiler Package A-4001A, A-4001B, A-4001C and A-4001D Four steam boilers are designed to produce High-High Pressure steam. The Maximum Continuous Rating (MCR) of each boiler is 196 T/h. The maximum steam capacity of each boiler is 110% of MCR which is 215.6 T/h The steam boiler packages consist of: 1. Four HHP Boilers to produce HHP steam 2. 4 x 100% Forced Draft Fans, two motors-driven, two turbines-driven 3. Economisers, soot blowers for cleaning the heating surface of boilers, stack. 4. Continuous blow-down drums D-4061/66, discontinuous blow-down drums D4067/68.

1.2.

Steam Turbine Generator Package A-4002A, A-4002B, A-4002C and A-4002D

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Four steam turbine generators are designed to generate power maximum 27 MW each, with maximum 50 T/h MP steam extraction. The steam turbine generator packages consist: a. Four steam turbine generators b. 4 x 100% turbine surface condenser to condense the turbine’s exhaust steam against sea cooling water. c. 8 x 100% condensate return pump (2 x 100% for each STG, one motor-driven, one turbine-driven) to pump the vacuum condensate to condensate collection tank in Unit 032 for condensate treatment. d. 4 x 100% Extracted MP steam de-superheater. 1.3.

High-High Pressure (HHP) / High Pressure (HP) Steam Letdown Station/ Desuperheater DS-4001 One HHP/ LP De-superheater is designed to letdown and de-superheat HHP steam to LP steam required during initial start up. The letdown station is designed for maximum LP steam flow rate of 112 T/h and minimum flow of 24 T/h

1.4.

HHP/ HP Steam Letdown Station/ De-superheater DS-4002A, DS-4002B, and DS4002C Three HHP/ HP de-superheater are designed to letdown and to de-superheat HHP steam to HP steam, which consist of: a. Two HHP de-superheater (DS-4002A and B) each designed for maximum HP steam low rate 39.8 T/h and minimum flow rate of 9.5 T/h b. One number of HHP/ HP de-superheater (DS-4002C) is designed for maximum HP steam flow rate of 128.7 T/h and minimum flow rate of 38.0 T/h

1.5.

High Pressure (HP)/ Medium Pressure (MP) Steam Letdown Station/ De-superheater DS-4003A and DS-4003B Two unit of HP/ MP de-superheater (one duty, one standby) are designed to letdown and de-superheat HP steam turbine drives. Each de-superheater is designed for maximum flow rate of 50.0 T/h

1.6.

Low Pressure (LP) Steam Letdown Station/ De-superheater DS-4004A and DS-4004B Two numbers of LP de-superheater (one duty, one standby) are designed to desuperheat LP steam exhaust from steam turbine drives. Each de-superheater is designed for maximum flow rate of 111.4 T/h

1.7.

High-High Pressure (HHP)/ Boiler Feed Water (BFW) De-aerator DA-4031 and DA 4032. Page 18 of 54


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2x 100% HHP BFW de-aerators each with maximum design capacity of 696 T/h are provided. De-aerator is designed for removal of dissolved gasses in HHP BFW supplied to boilers for HHP steam production. The de-aerator has storage capacity for 10 minutes hold-down between high and low liquid levels at maximum design flow rate. The dissolved oxygen content in treated water after de-aerator does not exceed 0.007ppm wt and the CO2 content is not detectable for all operating cases. The addition of oxygen scavenger removes this residual oxygen. 1.8.

HHP Boiler Feed Water Pumps P-4031, P-4032, P-4033 and P-4034. 4 pumps each with rated capacity of 269m³/ h are provided to supply HHP BFW from DA-4031/32 to boilers and HP BFW to de-superheaters. Two pumps (P-4031/33) are motor-driven and the other two (P-4032/34) are steam turbine-driven using HP steam exhaust. Two pumps are adequate in supplying HHP BFW under normal refinery operation (two on duty and one is standby) will be required to run in parallel if three boilers are to be operated at 100% MCR.

1.9.

Phosphate Dosing Unit A-4005A A-4005B, A-4005C and A-4005D. Phosphate is dossed into the steam drum of each HHP boiler for effective removal of scale. Phosphate dosing unit consist: a. Two phosphate storage tanks (one on duty, one is stand by) each capacity of 800L to store phosphate for four boilers b. 2 x 100% phosphate dosing pumps (one on duty, one is stand by) for each HHP boiler (total 8 phosphate dosing pumps)

1.10. Oxygen Scavenger Dossing Unit A-4006. Oxygen scavenger is used to remove residual dissolve oxygen in HHP BFW after the de-aerator. The oxygen scavenger is injected into common suction line of the HHP BFW pumps. Dosing operates at a preset flow adjusted manually by the operator when required. Oxygen scavenger dosing unit consist: a. One oxygen scavenger storage tank with capacity of 200L b. 2 x 100% Oxygen scavenger dosing pumps.

1.11. Ammonia Dosing Unit A-4007.

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Ammonia solution is injected into common suction line of HHP BFW pumps. Dosing pump operates at a preset flow adjusted manually by the operator when required. Ammonia dosing unit consist: a. One ammonia solution storage tank with capacity of 2.0m³ b. 2 x 100% ammonia solution dosing pumps. 1.12. Oily Water Lifting Pump P-4001. 1 x 100% oily water lift pump with rated capacity of 20m³/ h is provided to pump oily water from TK-4001 to effluent treatment plant (ETP) 1.13. De-aerator Overflow Pit TK-4001. De-aerator overflow pit has nominal capacity of 40m³. This pit collects manual drain from hot fluid sources in Unit 040 and oil spillages if any. 1.14. Diesel Fuel Oil Service Tank TK-4091. Diesel fuel service tank has a nominal capacity of 4.1m³ is equivalent to approximately 8 hours storage. This tank is designed for diesel fuel oil storage for emergency generator diesel. 1.15. Emergency Diesel Generator A-4008. Fuel Gas Knockout Drums D-4080A and D4080B. Emergency Diesel Generator is designed to generate power of 1.2MW to provide an emergency power supply during Emergency Shutdown of the refinery to emergency lighting, instrumentation/ control UPS battery charging, switchgear trip/ close DC supply equipment. 1.16. Fuel gas knockout Drums D-4080A and D-4080B Two number of fuel gas knockout drums are provided. The main function of these drums is to remove liquid droplets if any in fuel gas supply before being supplied to boilers. 1.1.

Location in the Plant.

All the power generators are located in Utility Area 6 at unit 40. The Steam, boiler feeder water and condensate are at unit 32, cooling water and fuel oil are at unit 33 and unit 38.

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1.2.

8474L-000-A5016-0000-001-301 REV: A DATE: 12/10/07

Location in the Process.

As a power generation of all systems of hardware and or software, those power generation is a mother of the process. In this case, it should be as a first place of all equipments driven by electrical power. Emergency Generator could be put in second line of the process due to it functions. This generator will activated simultaneously to supply electrical power when emergency shutdown for emergency lightings, Instruments control, UPS Battery Charging, switchgear trip/ closed DC Supply for equipments, etc. 1.3 Criticality. Since we were mentioned that The Electric Power Generations is a mother of the process, the criticality of equipment (electric generator) will be Vital for all system and process.



8474L-000-A5016-0000-001-301 REV: A DATE: 12/10/07


Course Content:





Section 4-


Section 5 -


X


SECTION 2: SPECIFICATION AND ARRANGEMENT Page 22 of 54


2.1.

8474L-000-A5016-0000-001-301 REV: A DATE: 12/10/07

Generators Model and Technical Specification.

2.1.1. The Steam Turbine Generators Steam Turbine Generator which used in this refinery plant were manufactured by Shin Nippon – Japan with Model: C9-R13-ER. 2.1.1.1.

General Specification:

a. Rated Power 27000KWe Generator Output b. Speed Rotation (Normal and at rated power 4922 rpm). c. Inlet Flow (rated 126000 Kg/ H and 125100 Kg/H at Normal) d. Inlet Pressure for normal is 105.5 Kg/ cm².g and 103.5 Kg/ cm².g at rated power e. Inlet temperature 500⁰C at normal and 495⁰C at rated power f. Induction/ Extraction Flow 50000 Kg/ H at normal and rated power g. Induction/ Extraction Pressure 15.1 Kg/ cm².g at normal and rated power h. Induction/ Extraction temperature 265⁰C at normal and rated power i. Exhaust Pressure 0.081 Kg/ cm².a at normal and rated power j. Induction/ Extraction temperature 41.4⁰C at normal and rated power k. Steam rate (Normal 4.633 Kg/kW-H) and (rated 4.466kg/ kW-H) l. Electrical Drive 400V, 3Phase and 50Hz m.Heating Power 400V/230V, 3Phase/1 phase and 50Hz For detail specification, refer to vendor datasheet/ manual: 8474L-040-SP-4121-001-1.

2.2.1. Diesel Engine Generator 2.2.1.1. The Diesel Engine Generator Manufacturer is Mitsubishi – Japan, with model: S16R-PTAA2. Generator’s General Specification: a. Driven Machine 1.6MWe (generator output) b. Rated power 1763 kW with speed 1500 rpm. c. Engine Cooling System Water Cooled d. Starting Method: Manual/ Automatic / electric and cold start aids e. Starting System: 2 unit Battery Starting with cable, and battery rating 400Ah/ each. For specification detail, refer to vendor datasheet/ manual: 8474L-040-SP-4123-001-0 2.2.. General Layout in Unit 040 Page 23 of 54


8474L-000-A5016-0000-001-301 REV: A DATE: 12/10/07

2.2.2. Steam Turbine Generator.

2.2.3. Diesel Generator Layout in Unit 040

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8474L-000-A5016-0000-001-301 REV: A DATE: 12/10/07


Course Content:





Section 4-


Section 5 -


X


SECTION 3: ELECTRIC GENERATOR OPERATION Page 26 of 54


8474L-000-A5016-0000-001-301 REV: A DATE: 12/10/07

In normal operation, 3 units STG are operated with maximum power 81MW and 1 unit standby as a spare. The generator shall be sufficient for continuous full load service, at rated power and specified ambient without exceeding the temperature rises in the standard rating. Relative humidity shall be taken 100% at temperature maximum 42⁰C. 3.1. Normal Operation. At normal operation, the generator must be able to provide the refinery with follows: a. Electric Power, including export of excess power via EVN grid link. b. High Pressure Steam c. Medium Pressure Steam, and d. Low Pressure Steam. Steam capacities of boilers are 4 x 196T/ h at 107kg/ cm²g and 505⁰C. Follow are normal operating steps: f. De-aeration of treated Power Station Condensate g. HHP Steam generation by boilers h. Electric Power Generation, and i. Steam Production. 3.2. Start up Procedure Various type of start up of the power generation is follow: a. HHP BFW De-aeration Start up (DA-4031/32; P-4031/32/33/34), b. Boilers Start up (A-4001A/B/C/D), c. Steam Turbine Generator Start up (A-4002A/B/C/D), and d. Letdown Station Start up (DS-4001; DS-4002A/B/C; DS-4003A/B; DS-4004A/B). 3.2.1. Start up preparation. Before starting generator, it is recommended to carry out preparation starting check list procedure, as determined by pre-commissioning or commissioning procedure. Refer to 8474L-040-ML-001-A Chapter 6 page 1-5 for specific detail start up procedure. 3.3. Shutdown Procedure. 3.3.1. Normal Shutdown Procedure. Power generation system unit 40 is designed to: a. De-aerate and produce HHP BFW and supply to steam boilers. b. Generate Electric Power Page 27 of 54


8474L-000-A5016-0000-001-301 REV: A DATE: 12/10/07

c. Steam Supply (HP, MP and LP) to s. Stoppage the entire Power Generation System would depend upon stoppage of refinery complex and upon request after that. 3.3.1.1. Boiler and STG Package. Boilers and STG are shutdown according to vendor’s safe shutdown procedure. Refer to vendor manual for specific detail. 3.3.1.2. Steam Header Open vents and drain. 3.3.1.3. HHP De-aerator. - Stop running pump (P-4031/32/33/34), - HHP De-aerator (DA-4031/32) filling will stop, - Disable the pump auto-start logic, - Stop LP Steam supply, - Stop the oxygen scavenger and ammonia injection by shutting down oxygen scavenger dosing package A-4006 and ammonia dosing package A-4007, as vendor procedure. - Isolate de-aerator DA-4031/32 - Fill the de-aerator with nitrogen to slight positive pressure and drain de-aerators. 3.3.2. Emergency Shutdown. 3.3.2.1. General Emergency Shutdown Refer to vendor document for boilers, steam turbine generator and HHP BFW pumps. 3.3.2.2. Instrument Air Failure Operator will be alerted by 032-PAL-086 on Instrument air header unit 032 battery limits. Loss of instrument air in the unit will be affect all pneumatic driven equipment mainly control valve and on/off valve.

The lists of safe failure mode of control valves installed in the unit distinguish per service: Page 28 of 54


8474L-000-A5016-0000-001-301 REV: A DATE: 12/10/07

Safe Failure Mode

Action

Letdown Valves Flow Control

Failure Close

Travel to close position

Letdown station HP BFW flow control

Failure Close


HP steam header flow control

Failure Close


LP steam to de-aerator flow control

Failure Close


Demineralised water to deaerator flow control

Failure Open

Travel to open position

LP steam header flow control

Failure Open

Travel to open position

Service

The lists of safe failure mode of on/ off valves installed in the unit distinguish per service: Service

Safe Failure Mode

Action

HP steam to pump steam turbine flow control

Failure Close

Travel position

to

close

Demineralised water to deaerator flow control

Failure Open

Travel position

to

open

3.3.2.3. Steam failure. Power Generation System is source of steam generation and this chapter is not applicable to this unit. 3.3.2.4. Electric Power Failure Power Generation System is source of steam generation and this chapter is not applicable to this unit. 3.3.2.5. Cooling Water Failure When cooling water failure, cooling media will not be available for the followings: a. Pumps seal plan, turbine bearing and cooler, b. Generator cooler, oil cooler, sampling cooler, heat exchanger for blow down drums. Monitor pump and Steam Turbine Generator operation and co-ordinate with Mechanical Supervisor to assess the impact of momentary shortage cooling water supply. 3.3.2.6. Sea Cooling Water failure. Page 29 of 54


8474L-000-A5016-0000-001-301 REV: A DATE: 12/10/07

In case of sea water cooling failure, cooling media for surface condenser of STG packages will not be available which leads to power shutdown. Operator shall coordinate with Utility supervisor to restore supply of sea cooling water. 3.3.2.7. Demineralised Water failure. When the demineralised water failure, no mineralised water make up to de-aerator DA-4031 and A-4032. STG continues run and slightly decrease capacity less to extend of demineralised water make up quantity. Operator shall coordinate with Utility supervisor to restore supply of demineralised water.



8474L-000-A5016-0000-001-301 REV: A DATE: 12/10/07


Course Content:





Section 4-


Section 5 -


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SECTION 4: ELECTRIC GENERATOR MAINTENANCE Page 31 of 54


8474L-000-A5016-0000-001-301 REV: A DATE: 12/10/07

In this section we are focusing on Generator Maintenance Procedure. Steam Turbine and Diesel Engine will specifically describe in mechanical rotating training section. Due to vendor maintenance manual under preparation, the preventive maintenance listed below is a general procedure/guide line of various types of Generator maintenance prevention. It will be specifically developed when vendor maintenance manual is available. 4.1. Maintenance Procedure Electric Generator maintenance procedure and schedules will be recommended in vendor manual. Electric Generator’s operator shall follow daily, weekly, monthly and all maintenance and recording frequencies mention in manual for reliable and excellent generator performance. 4.2. Electric Generator Preventive Maintenance This suggested preventive maintenance is a basic operation for all type of electric generator. In this case, preventive maintenance schedule and specific detail of PM operations of STG and EDG shall be carried out as vendor manuals recommended. No Process 1

Monthly

6 Month

Yearly

Lubrication Inspection Engine Crankcase inspection Visual check coolant contamination Change engine oil and filter (see vendor manual for √ more specific detail) Clean crankcase breather Lubricate generator bearing.

2

Cooling System - Check engine coolant level, top-up if necessary. - Inspect low coolant sensor (if fitted) - Check supplement coolant adhesive (SCA), add if required. - Inspect coolant lines and hoses condition

√

- Check Fan/ Alternator belt tension and wear. - Inspect fan idler pulley assembly; pivot and grease. - Inspect the cooling fan and grease the drive bearing, and inspect the fan hub for proper clearance. Page 32 of 54


8474L-000-A5016-0000-001-301 REV: A DATE: 12/10/07

- Inspect coolant pump and coolant element if required. - Inspect coolant block heater operation and record temperature. 3

Fuel System (for Diesel Engine) - Replace fuel filter (see vendor manual for specific detail) - Inspect main tank/ day tank (if applicable)

√

- Check piping and correct minor leakage. - Check pump, float switch, and level indicator.

4

Air Induction and Exhaust - Check the air cleaner and service indicator; Clean dust controller cap - Inspect manifold air piping, intake hoses and its clamps, intake exhaust opening

√

- automatic louver system if fitted, ensure louvers are wired to generator. 5

Electrical System - Check batteries electrolyte, cables, and connections and carry out load test and record. - Inspect alternator drive belt for tension and wear, shutoff control and starter function.

√

- Inspect battery charger function and indicator, refer to vendor manual for specific detail. 6

Engine and Alarm Verification - Record engine crank time, rpm, voltage, no load frequency. Do an adjustment if required. - Check and record engine oil pressure, operating temperature, and charging system. - visual indicator measurement Instrument Transmitter if fitted.

7

General Inspection

√

and

√ Page 33 of 54


8474L-000-A5016-0000-001-301 REV: A DATE: 12/10/07

- Inspect all belts and ensure for proper operations. - Inspect control for frayed or damage wires, overheating and termination loose. - Inspect the vibration dampers for rips, tears, broken, or leaks in liquids isolator. - Inspect generator and engine hold down bolts, oil and coolant leaks. - Replace battery (ies), replace air cleaners, and coolant flush. - Carry out oil analysis. - Carry out fuel analysis (for diesel only) - Load Bank test.

4.3. On Condition Maintenance Basically on condition maintenance is verification and recording essential instrument monitoring indicator of generators. This operation shall be carried out base on vendor manual. Whenever discrepancy found out, a corrective maintenance shall be done in immediate effect. Warning! 1. Before doing corrective maintenance, ensure all safety procedure and PPE requirement are applied. 2. Replace damage parts with original parts and follow thoroughly vendor manual instruction for safe and correct operation. 4.4. Inspection Requirement Routine inspection as per preventive and on condition maintenance with constant periodic will help the generator supplying all energy demand by refinery operations. Other inspection discipline will be taken in action base on specific subject, such as instrumentation control, mechanicals and other relevant process required.



8474L-000-A5016-0000-001-301 REV: A DATE: 12/10/07


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Section 4-


Section 5 -


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SECTION 5: ELECTRIC GENERATOR TEST & CALIBRATION Page 35 of 54


8474L-000-A5016-0000-001-301 REV: A DATE: 12/10/07

This Test and calibration instruction is general information for test and calibration requirement for common electric generators. Since the maintenance under prepared, all necessity test and calibration shall refer to the vendor maintenance manual when it available. Corresponding to actual test and calibration will be developed when vendor maintenance manual is available. Carrying test and calibration is to ensure the Power Generation System are capable to produce sufficient enough Electric Power and Steams Supplies to refinery operation, and maintain Generators in proper and efficiently operation, some parts of generators and component related to its operations shall be tested and calibrated in regular periodic. Test and inspection required for the generator: c. Winding resistant measurement d. Insulation Resistant measurement e. Shaft Voltage measurement f. Friction and wind age loss and core lose measurement g. Stray load lose measurement h. Telephone Harmonic factor (THF) measurement i. Total Harmonic Distortion (THD) measurement j. Noise Level Measurement k. Vibration Measurement l. Phase Sequence Inspection m. Voltage Balance Inspection n. Dimensional Inspection o. Painting Inspection p. Short Circuit Ratio determination q. Direct axis synchronous reactance determination r. Open circuit saturation Test s. Three phase short circuit saturation test t. Temperature rise test u. Over speed test v. High Voltage test w. Conventional Efficiency Calculation x. Space Heater Check y. Appearance Check z. Manufacturing data book verification. Test and calibrating process and frequencies are done base on equipments/ component vendor’s manuals requirement. Page 36 of 54


8474L-000-A5016-0000-001-301 REV: A DATE: 12/10/07

To avoid high of lost time for test and calibration process, some operation can be carried out with cross disciplines with same schedule of frequency. 5.1. Static Test Static test is a measurement taken under condition where neither the stimulus nor the environmental conditions fluctuate. For normal operation, static test mainly carry out for static energy source verification of battery power output, and charger refer to vendor manual and all static devices, such as manual valves, check valves, pressure safety valves and other instrument protective function installed related to power generator stop due to any deviated condition. (Base on normal operation monitoring and maintenance schedule frequency stated by manufacturer). 5.2. Dynamic Test Dynamic inspection also might be done during normal operation or refer to periodic maintenance schedule. However the operator is the one who detect any deviation of machines operation and parameters indication. Bearings noise, oil/ fuel level, oil/ fuel constrain, oil/fuel seepage, belts tension, visual indicators/ measurement, voltage balance, short circuit saturation, winding resistant, insulation resistant, frequency, safety devices, alarms function, fans, exhaust, piping system, anticondensation observation and record at daily basis are highly recommended. More specific detail of dynamic test will refer to vendor maintenance and troubleshooting manual. 5.3. Calibration. Essential equipments or components periodically calibration is required for maintaining generator in high efficiency and safe condition. Calibration process is to that all parameter measurement refer to original range of operations. Safety and Protective Devices (protective relays, circuit breakers, shutdown valves, grounding/ earthing system, environment pollutions/ temperature controller), and instruments measurement function, shall be calibrated with constant interval of calibration periodic to ensure all systems are work properly, efficiently and safe. More specific detail of individual components calibration will refer to each vendor’s manual and or local regulation basis. In some place and condition, calibration process shall be witness by third party.

TRAINING MODULE

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Course Content:





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Section 5 -


Section 6 - DIAGNOSTIC & TROUBLESHOOTING

X

Section 7 - SPARE PARTS AND CONSUMABLE Section 8 - SPECIAL TOOLS Part 5 - GLOSSARY/ ACRONYM

SECTION 6: DIAGNOSTIC AND TROUBLESHOOTING

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8474L-000-A5016-0000-001-301 REV: A DATE: 12/10/07

For these types of generator has specific design requirement. Due to Maintenance Manual is under preparation, all maintenance diagnostic and troubleshooting procedure shall be followed as per vendor maintenance manual/ instruction. 6.1. Troubleshooting Diagram Real Diagnostic and Troubleshooting procedure will be developed when vendor manual is available

Page 39 of 54


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TRAINING MODULE


Course Content:





Section 4-


Section 5 -


Section 6 - DIAGNOSTIC & TROUBLESHOOTING Section 7 - SPARE PARTS AND CONSUMABLE

X

Section 8 - SPECIAL TOOLS Part 3 - HSE Part 4 - REFERENCE DOCUMENTS INDEX Part 5 - GLOSSARY/ ACRONYM

SECTION 7: SPARE PARTS AND CONSUMABLE Page 40 of 54


8474L-000-A5016-0000-001-301 REV: A DATE: 12/10/07

7.1. Original Equipment Manufacturer (OEM)/ Generic Spare Parts OEM/ Generic Spare Part list is not available. It will be generated when vendor spare part list is available. 7.2. Consumable Consumable list is not available. It will be generated when vendor document is available.



8474L-000-A5016-0000-001-301 REV: A DATE: 12/10/07


Course Content:





Section 4-


Section 5 -


Section 6 - DIAGNOSTIC & TROUBLESHOOTING Section 7 - SPARE PARTS AND CONSUMABLE Section 8 - SPECIAL TOOLS

X

Part 3 - HSE Part 4 - REFERENCE DOCUMENTS INDEX Part 5 - GLOSSARY/ ACRONYM

SECTION 8: SPECIAL TOOLS 8.1. List of Special Tools Page 42 of 54


8474L-000-A5016-0000-001-301 REV: A DATE: 12/10/07

List of special tools are not available yet. It will be generated when vendor list is available. 8.2. Maintenance, Calibration, Certification and Storage of Special Tools. List of special tools are not available yet. It will be generated when vendor list is available.

TRAINING MODULE

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8474L-000-A5016-0000-001-301 REV: A DATE: 12/10/07

MAINTENANCE MODULES ELECTRICAL GENERATORS Course Content:





Section 4-


Section 5 -


Section 6 - DIAGNOSTIC & TROUBLESHOOTING Section 7 - SPARE PARTS AND CONSUMABLE Section 8 - SPECIAL TOOLS Part 3 - HSE

X

Part 4 - REFERENCE DOCUMENTS INDEX Part 5 - GLOSSARY/ ACRONYM

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8474L-000-A5016-0000-001-301 REV: A DATE: 12/10/07

PART 3: HSE 3.1. Equipment Related Safety Issues Generator location is a Hazardous Zone; please wear relevant Personal Protection Equipments such as Ear Plugs, Safety Shoes, Hand Gloves, etc, for daily operation. 3.2. Maintenance Workshops Safety Equipment. Before carrying any maintenance activity, test and calibration, read thoroughly safety advises by vendor manual. Specific tools for safety purposes might be required and it recommended for application. HSE procedure, Equipment Related Safety Issues, and Maintenance Workshop Safety Equipment are not available yet. It will be generate when the vendor manual is available.

Page 45 of 54


8474L-000-A5016-0000-001-301 REV: A DATE: 12/10/07

TRAINING MODULE


Course Content:





Section 4-


Section 5 -


Section 6 - DIAGNOSTIC & TROUBLESHOOTING Section 7 - SPARE PARTS AND CONSUMABLE Section 8 - SPECIAL TOOLS Part 3 - HSE Part 4 - REFERENCE DOCUMENTS INDEX

X

Part 5 - GLOSSARY/ ACRONYM

Page 46 of 54


8474L-000-A5016-0000-001-301 REV: A DATE: 12/10/07

PART 4. REFERENCE DOCUMENTS INDEX

4.1.

4.2.

Vendor Document 8474L-040-ML-001-A

Operating Manual Power Generation

TIP Y06GF416

Testing Procedure for Generator

Arrangement Drawing, Layout and Plot Plans 8474L-040-DW-0052-002-0

Equipment Arrangement Unit 040 Power and Steam Generator

8474L-040-PID-0021-041-C

Emergency Generator Layout

4.3.

Process/ Utility Flow Diagram (PFD/ UFD)

4.4.

Piping & Instrument Diagram (P& ID)

4.5.

Equipment List

4.6.

Main Equipment Datasheet 8474L-040-SP-4121-001-01

Mechanical Datasheet for Turbine Generator Package.

Steam

8474L-040-SP-4123-001-00

Datasheet Generator

Diesel

8474L-040-JSS-4212-001-1

Job Specification for Supply Steam Turbine Generator Package

4.7.

Instrument List

4.8.

MSDS

4.9.

3D Drawings -

Dung Quat Refinery Project

-

Online Britannica Encyclopedia

-

Shin Nippon Website

-

Mitsubishi Power Generator Website

for

Emergency

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Section 4-


Section 5 -



X

Page 48 of 54

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8474L-000-A5016-0000-001-301

GENERATORS

REV: A DATE: 12/10/07

PART 5. GLOSSARY/ ACRONYM Acronyms COMPANIES/ORGANISATIONS DQR

Dung Quat Refinery

DQIZMB

Dung Quat Industrial Zone Management Board

EVN

Electricity Authority of Vietnam

FW

Foster Wheeler Energy Limited

MOC

Ministry of Construction

MOSTE

Ministry of Science, Technology and Environment

MPI

Ministry of Planning and Investment

SRV

Socialist Republic of Vietnam

TPC

Technip Consortium

OTHERS ACE

Application Control Environment

MC

Marshalling Cabinet

ADAS

Analyser Data Acquisition System

MCB

Main Control Building

ADP

Alarm Display

MCC

Motor Control Center

AER

Application Engineers Room

MCR

Main Control Room

AI

Analyser Indicator

MCS MOV Control System

MOV Control System

AIT

Auto Ignition Temperature

MDF

Main Distribution Frame

AMS

Asset Management System

MIS

Management Information System

ANSI

American National Standards institute

MMS

Machine Monitoring System

APC

Advanced Process Control

MMT

Minimum Maintained Temperature

API

American Petroleum Institute

MOC

Madrid Operating Center Page 49 of 54

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GENERATORS

REV: A DATE: 12/10/07

ARU

KEROSENE TREATER UNIT (KTU)

MOM

Minutes of Meeting

ASC

Analyser Speciality Contractor

MOV

Motor Operated Valve

ASME

American Society of Mechanical Engineers

MP

Medium Pressure

ASP

Analyser Systems Package

MPT

Minimum Pressurization Temperature

ASTM

American Society of Testing and Materials

MR

Material Requisition

ATM

Asynchronous Transfer Mode

MRR

Marshalling Rack Room

BCS

Blending Control System

MSD

Material Selection Diagram

BEDD

Basic Engineering Design Data

MSDS

Material Safety Data Sheet

BFD

Block Flow Diagram

MTBF

Mean Time Between Failures

BFW

Boiler Feed Water

MTTR

Mean Time To Repair

BL

Battery Unit

MTO

Material Take-Off

BOM

Bill of Materials

MTPA

Metric Tonnes per Annum

BPC

Blending Properties Control

MVIP

Multi Vendor Interface Program (Honeywell)

BPCD

Barrels per Calendar Day

NACE

National Association of Corrosion Engineers

BPSD

Barrels per Stream Day

NCR

Non Conformance Report

BRC

Blending Ratio Control

NDE

Non Destructive Examination

CAD

Computer Aid Design

NFPA

National Fire Protection Association

CALM

Catenary Anchor Leg Mooring

NHT

Naphtha Hydrotreater (Unit)

CBT

Commercial Bid Tabulation

NIR

Near Infrared Spectroscopy

CCAR

Control Complex Auxiliary Room

NPSH

Net Positive Suction Head

CCC

Central Control Complex

NPV

Net Present Value

CCR

Continuous Catalytic Reformer

NTU

Naphtha Treater Unit

CCTV

Closed Circuit Television

OAS

Oil ing System

CD

Chart Datum

OJT

On Job Training

CDU

Crude Distillation Unit

OM&S

Oil Movement and Storage Control System

CENELEC

European Committee for Electrotechnical Standardization

OMSA

Oil Movement and Storage automation

CFC

Chlorofluorocarbons

OOS

Operation Override Switch Page 50 of 54

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GENERATORS

REV: A DATE: 12/10/07

CFR

Cooperative Fuel Research (Engine)

OPSS

Operations Planning and Scheduling System

C&I

Control and Instrumentation

OSBL

Outside Battery Limit

CMMS

Computerized Maintenance Management System

OTS

Operator Training Simulator

CNU

(Spent) Caustic Neutralization Unit

PABX

Private Automatic Branch Exchange

I

Corrugated Plate Interceptor

PAGA

Public Address / General Alarm

CSI

Control Systems Integrator

PCB

Printed Circuit Board

DAF

Dissolved Air Flotation

PFD

Process Flow Diagram

DAU

Data Acquisition Unit

PFM

Path Find Module

DCS

Distributed Control System

PDB

Project Documents Base

DEA

Diethanolamine

PGC

Process Gas Chromatograph (Analysers)

DEIA

Detailed Environmental Impact Assessment

PHD

Plant History Database

DMDS

Dimethyldisulfide

PI

Plant Air

DMS

Document Management System

PIB

Process Interface Building

DNV

Det Nork Veritas

PID

Piping and Instrument Diagram

DPTD

Design, Pressure, Temperature Diagram

PIM

Project Implementation Manual

DQMIS

Dung Quat Management Information System

PKS

Process Knowledge System (Honeywell DCS)

DQRP

Dung Quat Refinery Project

PLEM

Pipeline End Manifold

DVM

Digital Video Manager

PLG

Planning

DWT

Dead Weight Tonnes

PMC

Project Management Consultant

EL

Equipment List

PMI

Positive Material Identification

EOR

End of Run

PMT

Project Management Team

EDMS

Electronic Document Management System

PO

Purchase Order

EMC

Electromagnetic Compatibility

POC

Paris Operating Center

EPC

Engineering Procurement, Construction and Commissioning

PP

Project Procedure

ERP

Enterprise Resource Planning

PPB

Parts per Billion Page 51 of 54

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GENERATORS

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ES

Ethernet Switch

PPM

Parts per Million

ESD

Emergency Shut Down

PRU

Propylene Recovery Unit

ETP

Effluent Treatment Plant

PWHT

Post Weld Heat Treatment

ETS

Effluent Treatment System

QA

Quality Assurance

EWS

Engineering Work Station

QC

Quality Control

FDC

Feed Development Contract

RA

Risk Analysis

FAP

Fire Alarm

R&D

Research and Development

FAT

Factory Acceptance Test

RDBMS

Real Time Database Management System

FEL

Front End Loading

RFCC

Residue Fluid Catalytic Cracking

F&G

Fire and Gas System

RFSU

Ready for Start-Up

FIU

Field Interface Unit

RLU

Remote Line Unit

FIC

Flow Indicating Controller

ROW

Right of Way

FM

Factory Mutual (Approval body)

RPMS

Refinery Performance Management System

FOTC

Fibre Optic Termination Cabinet

RTD

Resistance Temperature Detector

FSC

Fail Safe Controller (Honeywell ESD)

RTDB

Real Time Data Base (System)

FTE

Fault Tolerant Ethernet

RTU

Remote Terminal Unit

GC

Gas Chromatograph

SAT

Site Acceptance Test

GFT

Ground Fault

SBT

Segregated Ballast Tanks

HAZAN

Hazard Analysis Study

SBMS

Software By Management System

HAZOP

Hazard and Operability Study

SCADA

Supervisory Control and Data Acquisition

HDT

Hydrotreater

SCC

Satellite Control Complex

HEI

Heat Exchange Institution

SCE

Simulation Control Environment

HHP

High High Pressure (Steam)

SCR

Satellite Control Room

HGO

Heavy Gas Oil

SDH

Synchronous Digital Hierarchy

HIC

Hydrogen Induced Cracking

SE

Safety Earth

HP

High Pressure

S&E

Safety & Environmental

HSE

Health, Safety and Environment

SGS

Safeguarding System

HVAC

Heating Ventilation Air Conditioning

SOE

Sequence of Events Page 52 of 54

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GENERATORS

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IA

Instrument Air

SOR

Start of Run

ICAO

International Civil Aviation Organisation

SOW

Scope of Work

ICE

Instrument Clean Earth

SP

Specification

ICS

Integrated Control System

SPIR

Spare Parts and interchangeability Record

IIP

Initial Interface Plan

SPM

Single Point Mooring

I/O

Input/Output

SR

Scope of Supply

IP

Institute of Petroleum

SRU

Sulphur Recovery Unit

IPS

Instrumented Protective System

STC

Construction Standard

IRP

Interposing Relay

STD

Design Standard

IRR

Internal Rate of Return

STEL

Short Term Exposure Limit

IS

Intrinsically Safe

SVAC

Shelter Ventilation and Air Conditioning

ISA

Instrument Society of America

ISE

Intrinsically Safe Earth

SWS

Sour Water Stripping (Unit)

ISBL

Inside Battery Limit

TAS

Terminal Automation System

ISOM

Isomerisation Unit

TBT

Technical Bid Tabulation

ITB

Invitation to Bid

TCF

Temporary Construction Facilities

ITP

Inspection and Test Plan

TCM

Task Control Module

JB

Junction Box

TEMA

Tubular Exchanger Manufacturers' Association

JCC

Jetty Control Complex

TGIF

Temperature Gauge Indication Facilities (Tankage)

JCR

Jetty Control Room

TLCR

Truck Loading Control Room

JSD

Job Specification for Design

TLCS

Truck Loading Control System

JSS

Job Specification for Supply

TN

Transmittal Note

JVD

t Venture Directorate

TPS

Total Plant Solution (Honeywell)

KLOC

Kuala Lumpur Operating Center

TQM

Total Quality Management

KTU

Kerosene Treatment Unit

TS

Terminal Server

LAN

Local Area Network

TWA

Time Weighted Average

LCO

Light Cycle Oil

UFD

Utility Flow diagram

LCOHDT

LCO Hydrotreater

U/G

Underground

System (Analyser houses)

Page 53 of 54

TRAINING MODULE

8474L-000-A5016-0000-001-301

GENERATORS

REV: A DATE: 12/10/07

LDE

Lead Discipline Engineer

UL

Underwriter Laboratories (Approval body)

LEL

Lower Exposition Limit (F&G, Analysers)

UPS

Uninterruptible Power Supply

LGO

Light Gas Oil

VDU

Visual Display Unit

LIMS

Laboratory Information Management System

VPU

Vendor Package Unit

LIS

Laboratory Information System

WABT

Weight Average Bed Temperature

LLU

Local Line Unit

WBS

Wash Breakdown Structure

LP

Low Pressure

WHB

Waste Heat Boiler

LPG

Liquefied Petroleum Gas

YOC

Yokohama Operating Center

LTU LPG

Treater Unit

Glossary Refer to glossary given separately.

Page 54 of 54

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