Generators Rev.A

ARAMIS Development Ltd
Vendor Document No.
Rev.
Page
TPC-DQR-002-TRM-MNT-301
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:
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.
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

GENERATORS
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
TRAINING MODULE
GENERATORS
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.
Page 3 of 54
TRAINING MODULE
GENERATORS
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
TRAINING MODULE
GENERATORS
8474L-000-A5016-0000-001-301
REV: A DATE: 12/10/07
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
Page 5 of 54
TRAINING MODULE
GENERATORS
8474L-000-A5016-0000-001-301
REV: A DATE: 12/10/07
TRAINING MODULE

GENERATORS
Course Content:
Part 1 - ELECTRIC GENERATOR TYPES

Part 2 Section 1 -
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
Page 6 of 54
TRAINING MODULE
GENERATORS
8474L-000-A5016-0000-001-301
REV: A DATE: 12/10/07
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
Page 7 of 54
TRAINING MODULE
GENERATORS
1.1.
8474L-000-A5016-0000-001-301
REV: A DATE: 12/10/07
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
TRAINING MODULE
GENERATORS
8474L-000-A5016-0000-001-301
REV: A DATE: 12/10/07
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 feedback loop continues to increase field voltage and output power until the
generator reaches its full operating output level.
This initial self-excitation feedback 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.
Page 9 of 54
TRAINING MODULE
GENERATORS
8474L-000-A5016-0000-001-301
REV: A DATE: 12/10/07
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 Panels
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 user
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
TRAINING MODULE
GENERATORS
8474L-000-A5016-0000-001-301
REV: A DATE: 12/10/07
Jobs, Dependencies, Job Streams and users.

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 user, Number of simultaneous jobs allowed for a
user, 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 user (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 user
is freed from the requirement to take the phone to a shop or service center to re-flash or
update.
1.5.
Generator Control Panel
An electric switchboard is a device that directs electricity from one source to another. It is an
assembly of panels, 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
TRAINING MODULE
GENERATORS
8474L-000-A5016-0000-001-301
REV: A DATE: 12/10/07
TRAINING MODULE

GENERATORS
Course Content:

Part 2 Section 1 -

GENERATOR

Section 3 -
Section 4-
Section 5 -

CALIBRATION

Part 3 - HSE
Part 5 - GLOSSARY/ ACRONYM
PART 2: STEAM TURBINE & DIESEL ENGINE GENERATOR

Page 12 of 54
TRAINING MODULE
GENERATORS
8474L-000-A5016-0000-001-301
REV: A DATE: 12/10/07
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
TRAINING MODULE
GENERATORS
8474L-000-A5016-0000-001-301
REV: A DATE: 12/10/07
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 bypassed.
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
TRAINING MODULE
GENERATORS
8474L-000-A5016-0000-001-301
REV: A DATE: 12/10/07
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.
TRAINING MODULE
Page 15 of 54
TRAINING MODULE
GENERATORS
8474L-000-A5016-0000-001-301
REV: A DATE: 12/10/07

GENERATORS
Course Content:

Part 2 Section 1 -

GENERATOR

Section 3 -
Section 4-
Section 5 -

CALIBRATION

Part 3 - HSE
SECTION 1: ELECTRIC GENERATOR IDENTIFICATION
Page 16 of 54
TRAINING MODULE
GENERATORS
8474L-000-A5016-0000-001-301
REV: A DATE: 12/10/07
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/Cmg and 505C. 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
Page 17 of 54
TRAINING MODULE
GENERATORS
8474L-000-A5016-0000-001-301
REV: A DATE: 12/10/07
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 turbines 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
TRAINING MODULE
GENERATORS
8474L-000-A5016-0000-001-301
REV: A DATE: 12/10/07
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 269m/ 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.
Page 19 of 54
TRAINING MODULE
GENERATORS
8474L-000-A5016-0000-001-301
REV: A DATE: 12/10/07
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 2.0m
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 20m/ 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 40m. 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 4.1m 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.
Page 20 of 54
TRAINING MODULE
GENERATORS
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.
TRAINING MODULE
Page 21 of 54
TRAINING MODULE
GENERATORS
8474L-000-A5016-0000-001-301
REV: A DATE: 12/10/07

GENERATORS
Course Content:

Part 2 Section 1 -

GENERATOR

Section 3 -
Section 4-
Section 5 -

CALIBRATION

Part 3 - HSE
SECTION 2: SPECIFICATION AND ARRANGEMENT

Page 22 of 54
TRAINING MODULE
GENERATORS
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/ cm.g and 103.5 Kg/ cm.g at rated power
e. Inlet temperature 500C at normal and 495C at rated power
f. Induction/ Extraction Flow 50000 Kg/ H at normal and rated power
g. Induction/ Extraction Pressure 15.1 Kg/ cm.g at normal and rated power
h. Induction/ Extraction temperature 265C at normal and rated power
i. Exhaust Pressure 0.081 Kg/ cm.a at normal and rated power
j. Induction/ Extraction temperature 41.4C 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.
Generators 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
TRAINING MODULE
GENERATORS
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
Page 24 of 54
TRAINING MODULE
GENERATORS
8474L-000-A5016-0000-001-301
REV: A DATE: 12/10/07
TRAINING MODULE
Page 25 of 54
TRAINING MODULE
GENERATORS
8474L-000-A5016-0000-001-301
REV: A DATE: 12/10/07

GENERATORS
Course Content:

Part 2 Section 1 -

GENERATOR

Section 3 -
Section 4-
Section 5 -

CALIBRATION

Part 3 - HSE
SECTION 3: ELECTRIC GENERATOR OPERATION

Page 26 of 54
TRAINING MODULE
GENERATORS
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 42C.
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/ cmg and 505C.
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
TRAINING MODULE
GENERATORS
8474L-000-A5016-0000-001-301
REV: A DATE: 12/10/07
c. Steam Supply (HP, MP and LP) to users.

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 vendors 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
TRAINING MODULE
GENERATORS
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
TRAINING MODULE
GENERATORS
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.
TRAINING MODULE
Page 30 of 54
TRAINING MODULE
GENERATORS
8474L-000-A5016-0000-001-301
REV: A DATE: 12/10/07

GENERATORS
Course Content:

Part 2 Section 1 -

GENERATOR

Section 3 -
Section 4-
Section 5 -

CALIBRATION

Part 3 - HSE
SECTION 4: ELECTRIC GENERATOR MAINTENANCE

Page 31 of 54
TRAINING MODULE
GENERATORS
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 Generators 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.
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
TRAINING MODULE
GENERATORS
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.
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
- Verify 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.
- Verify visual indicator measurement
Instrument Transmitter if fitted.
General Inspection
and
Page 33 of 54
TRAINING MODULE
GENERATORS
8474L-000-A5016-0000-001-301
REV: A DATE: 12/10/07
- Inspect all belts and ensure for proper operations.

- Inspect control panel 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.
TRAINING MODULE
Page 34 of 54
TRAINING MODULE
GENERATORS
8474L-000-A5016-0000-001-301
REV: A DATE: 12/10/07

GENERATORS
Course Content:

Part 2 Section 1 -

GENERATOR

Section 3 -
Section 4-
Section 5 -

CALIBRATION

Part 3 - HSE
SECTION 5: ELECTRIC GENERATOR TEST & CALIBRATION

Page 35 of 54
TRAINING MODULE
GENERATORS
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
vendors manuals requirement.
Page 36 of 54
TRAINING MODULE
GENERATORS
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 verify 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 vendors manual
and or local regulation basis. In some place and condition, calibration process shall be
witness by third party.
TRAINING MODULE
Page 37 of 54
TRAINING MODULE
GENERATORS
8474L-000-A5016-0000-001-301
REV: A DATE: 12/10/07

GENERATORS
Course Content:

Part 2 Section 1 -

GENERATOR

Section 3 -
Section 4-
Section 5 -

CALIBRATION

SECTION 6: DIAGNOSTIC AND TROUBLESHOOTING
Page 38 of 54
TRAINING MODULE
GENERATORS
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
TRAINING MODULE
GENERATORS
8474L-000-A5016-0000-001-301
REV: A DATE: 12/10/07
TRAINING MODULE

GENERATORS
Course Content:

Part 2 Section 1 -

GENERATOR

Section 3 -
Section 4-
Section 5 -

CALIBRATION


Part 3 - HSE
SECTION 7: SPARE PARTS AND CONSUMABLE

Page 40 of 54
TRAINING MODULE
GENERATORS
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.
TRAINING MODULE
Page 41 of 54
TRAINING MODULE
GENERATORS
8474L-000-A5016-0000-001-301
REV: A DATE: 12/10/07

GENERATORS
Course Content:

Part 2 Section 1 -

GENERATOR

Section 3 -
Section 4-
Section 5 -

CALIBRATION

Part 3 - HSE
SECTION 8: SPECIAL TOOLS

8.1. List of Special Tools
Page 42 of 54
TRAINING MODULE
GENERATORS
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
Page 43 of 54
TRAINING MODULE
GENERATORS
8474L-000-A5016-0000-001-301
REV: A DATE: 12/10/07

GENERATORS
Course Content:

Part 2 Section 1 -

GENERATOR

Section 3 -
Section 4-
Section 5 -

CALIBRATION

Part 3 - HSE

Page 44 of 54
TRAINING MODULE
GENERATORS
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
TRAINING MODULE
GENERATORS
8474L-000-A5016-0000-001-301
REV: A DATE: 12/10/07
TRAINING MODULE

GENERATORS
Course Content:

Part 2 Section 1 -

GENERATOR

Section 3 -
Section 4-
Section 5 -

CALIBRATION

Part 3 - HSE
Page 46 of 54
TRAINING MODULE
GENERATORS
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
Page 47 of 54
TRAINING MODULE
GENERATORS
8474L-000-A5016-0000-001-301
REV: A DATE: 12/10/07
TRAINING MODULE

GENERATORS
Course Content:

Part 2 Section 1 -

GENERATOR

Section 3 -
Section 4-
Section 5 -

CALIBRATION

Part 3 - HSE
Page 48 of 54
TRAINING MODULE
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 Panel
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
TRAINING MODULE
8474L-000-A5016-0000-001-301
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 Accounting 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
TRAINING MODULE
8474L-000-A5016-0000-001-301
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
CPI
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
TRAINING MODULE
8474L-000-A5016-0000-001-301
GENERATORS
REV: A DATE: 12/10/07
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 Panel
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 Bypass 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
TRAINING MODULE
8474L-000-A5016-0000-001-301
GENERATORS
REV: A DATE: 12/10/07
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 Panel
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
Joint 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

Generators Rev.A

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Generators Rev.A

Uploaded by

Copyright:

Available Formats

ARAMIS Development Ltd

Vendor Document No.

MAINTENANCE MODULES ELECTRICAL

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

Purchase Order Number:

Equipment / Item Tag:

TPC Document Number:

Issue for review

Pages changed in this

MAINTENANCE MODULES ELECTRICAL

PART 1: ELECTRICAL GENERATOR TYPES....................................................................... 7

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Maintenance, Calibration, Certification, Storage of Special Tools ............ 43

MAINTENANCE MODULES ELECTRICAL

Part 1 - ELECTRIC GENERATOR TYPES

STEAM TURBINE & DIESEL ENGINE

Section 2 - SPECIFICATION AND ARRANGEMENT

ELECTRIC GENERATOR OPERATION

ELECTRIC GENERATOR MAINTENANCE

ELECTRIC GENERATOR TEST &

Section 6 - DIAGNOSTIC & TROUBLESHOOTING

PART 1: ELECTRIC GENERATOR TYPES

Shin Nippon Condensing Multistage Steam Turbine

3 PHAES SYNCHRONOUS GENERATOR

Synchronous Generator Operation

Permanent Magnet Generator

Load Sharing Panels

Jobs, Dependencies, Job Streams and users.

Generator Control Panel

MAINTENANCE MODULES ELECTRICAL

Part 1 - ELECTRIC GENERATOR TYPES

STEAM TURBINE & DIESEL ENGINE

ELECTRIC GENERATOR IDENTIFICATION

Section 2 - SPECIFICATION AND ARRANGEMENT

ELECTRIC GENERATOR OPERATION

ELECTRIC GENERATOR MAINTENANCE

ELECTRIC GENERATOR TEST &

Section 6 - DIAGNOSTIC & TROUBLESHOOTING

PART 2: STEAM TURBINE & DIESEL ENGINE GENERATOR

There are two kinds of generator using in this refinery plant.

MAINTENANCE MODULES ELECTRICAL

Part 1 - ELECTRIC GENERATOR TYPES

STEAM TURBINE & DIESEL ENGINE

Section 2 - SPECIFICATION AND ARRANGEMENT