DOCUMENT STATUS : FOR REFERENCE

B A Rev.

14-Jun-10 10-May-10
Date

RE-ISSUED FOR REFERENCE ISSUED FOR REFERENCE Description

SAARD O. SAARD O. Prepd.

KRIT K. KRIT K. Chkd.

SUMETH Y. SUMETH Y. Appd.

Project : Owner :

NHON TRACH 2 - 750MW COMBINED CYCLE POWER PLANT PROJECT

Consultant: PETRO VIETNAM NHON TRACH 2 POWER JOINT STOCK COMPANY

/ PECC2

EPC Contractor:

LILAMA PVC CONSORTIUM

Consultant:

FICHTNER GmbH & Co.KG

Subcontractor :

CONNELL WAGNER (AURECON)

TORISHIMA - AFCOLENCO - LILAMA 18 JSC.

Document Title : TRAINING MANUAL WTP & WWTP MONITORING, MAINTENANCE & TROUBLESHOOTING
Project No : NT 2 Designed by : Torishima Consortium Format : A4 Total Pages : 34 Checked by :

Function
Approved Checked Prepared

Name
Sumeth Y. Krit K. Saard O.

Sign

Date
14-Jun-10 14-Jun-10 14-Jun-10

Function
SM LME QA/QC

Name

Sign

Date

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

Date: 14-Jun-10

Rev. B

Page A

TORISHIMA AF COLENCO-LILAMA 18 JSC

76 BUI THIXUAN,HAI BA TRUNG DISTRICT, HANOI, VIETNAM Tel : 84-4-943 7880 Fax : 84-4-943 7875/7876

TRAINING MANUAL FOR WTP & WWTP MONITORING, MAINTENANCE & TROUBLESHOOTING
Rev. B : June 14, 2010

Torishima-AF Colenco-Lilama 18 JSC

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

Page B

TORISHIMA AF COLENCO-LILAMA 18 JSC

76 BUI THIXUAN,HAI BA TRUNG DISTRICT, HANOI, VIETNAM Tel : 84-4-943 7880 Fax : 84-4-943 7875/7876

NHON TRACH 2 - WTP & WWTP TRAINING PROGRAM

1) OBJECTIVE :

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

2) ATTENDEES:

No.

Training Program

Trainees Specialty

Total Number

Water and Waste water treatment Operation and maintenance

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

Page C

TORISHIMA AF COLENCO-LILAMA 18 JSC

76 BUI THIXUAN,HAI BA TRUNG DISTRICT, HANOI, VIETNAM Tel : 84-4-943 7880 Fax : 84-4-943 7875/7876

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

Venue: ORGANO ASIA SHAH ALAM OFFICE (MALAYSIA)

Day 1 4th July 2010 Arrival of Trainees at Kuala Lumpur, Malaysia & Hotel Check in. Day 2 5th July 2010
Time 10:00a.m - 12:30p.m 12:30p.m - 1:30p.m 1:30p.m - 3:00p.m 3:00p.m - 3.15p.m 3:15p.m - 4.00p.m Activity Introduction to Water Treatment System Lunch Break Cont Introduction to Water Treatment System Break Q&A Session

Day 3 6th July 2010

Time 10:00a.m - 12:30p.m 12:30p.m - 1:30p.m 1:30p.m - 3:00p.m 3:00p.m - 3.15p.m 3:15p.m - 4.00p.m Activity Introduction to Waste Water Treatment System Lunch Break Cont Introduction to Waste Water Treatment System Break Q&A Session

Day 4 7th July 2010

Time 10:00a.m - 12:30p.m 12:30p.m - 1:30p.m 1:30p.m - 3:00p.m 3:00p.m - 3.15p.m 3:15p.m - 4.00p.m Activity Water Treatment Plant Operation through HMI Graphic Display Lunch Break Cont Water Treatment Plant Operation through HMI Graphic Display Break Q&A Session

Page D

TORISHIMA AF COLENCO-LILAMA 18 JSC

76 BUI THIXUAN,HAI BA TRUNG DISTRICT, HANOI, VIETNAM Tel : 84-4-943 7880 Fax : 84-4-943 7875/7876

Day 5 8th July 2010

Time 10:00a.m - 12:30p.m 12:30p.m - 1:30p.m 1:30p.m - 3:00p.m 3:00p.m - 3.15p.m 3:15p.m - 4.00p.m Activity Waste Water Treatment Plant Operation through HMI Graphic Display Lunch Break Cont Waste Water Treatment Plant Operation through HMI Graphic Display Break Q&A Session

Day 6 9th July 2010

Time 10:00a.m - 12:30p.m 12:30p.m - 1:30p.m 1:30p.m - 3:00p.m 3:00p.m - 3.15p.m 3:15p.m - 3.30p.m 3.45p.m 5.00p.m Activity WTP & WWTP Monitoring, Maintenance & Troubleshooting Lunch Break WTP & WWTP Monitoring, Maintenance & Troubleshooting Break Q&A Session Test

Day 7 10th July 2010 Spare Day for Training Day 8 11th July 2010 Hotel Check Out & Departure of Trainee from Kuala Lumpur, Malaysia.

Page E

Nhon Trach 2 CCPP Project WTP & WWTP Plant MAINTENANCE MANUAL

Page 1 of 29

MAINTENANCE of WATER TREATMENT PLANT

Page 2 of 29

MONITORING AND MAINTENANCE REQUIREMENT

Item Data collection Check Daily Procedure Record down Daily Performance Log Sheet for Raw Water Treatment. Check the status and opening condition of equipment and instruments form control panel. Control Panel Daily Visually check the PANEL display indication, local flow indicators and pressure indicators. Acknowledge any alarm signals and take the appropriate corrective action. Operation personnel should confirm that the automatic operation is done correctly. System Area Rotating Equipment Chemical consumption Calibrate instruments Sample analysis for water quality Lubricant requirement (Blower) Daily Daily Daily Annually Monthly Proper housekeeping and clean up the spillage. Observe for abnormal noise, vibration, surface temperature, and lubricant level if necessary. Ensure the operating condition such like operating flow rate and discharge pressure as per design. Observe chemical tank level daily. Replenish chemical when necessary. Contact entire instrument supplier for calibration. Send the water sample to the laboratory for analysis Apply hydraulic oil or grease into the motor gearbox when oil level below the requirement level. Please refer to the individual equipment manual Record the MB Regeneration step. If the MB Regeneration failed, the DM supply will stop

Monthly

MB Regeneration Process

Daily

Page 3 of 29

Monitoring & Troubleshooting

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

System) Equipment Breakdown/Fault

Page 4 of 29

Service Throughput Shortage

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

Page 5 of 29

Poor Water Quality

Conductivity & Silica still High after Regeneration Why ?

Page 6 of 29

Rotating Equipment Troubleshooting

Page 7 of 29

Valve & Actuator Troubleshooting

Page 8 of 29

Valve & Actuator Troubleshooting (Cont)

Page 9 of 29

Valve & Actuator Troubleshooting (Cont)

Page 10 of 29

Conductivity & pH Sensor Troubleshooting

Page 11 of 29

Conductivity & pH Sensor Troubleshooting (Cont)

General Maintenance Procedure for Sensor

1. Clean a) Rinse sensor in plain water b) Use domestic cleaning agent to clean off coating deposits. deposits. c) The electrode must be rinsed thoroughly with clean water water to avoid contamination of the calibration solution. 2. Check a) Check the sensor with standard solution.If reading is within the accuracy, sensor can be put back on line. Else proceed to calibration. 3. Calibration a) Immersed clean electrodes in standard solution and let let it stabilize. b) Adjust transmitter reading to the calue of standard solution

Page 12 of 29

Switches Troubleshooting
1.

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

Page 13 of 29

Switches Troubleshooting (Cont)

1.

Level Switch - Make sure switches working fine, if not replace new one. - Simulate level by adjusting the float /Rod sensor and monitor the simulate level in VDU.

Page 14 of 29

PLC & I/O Module Troubleshooting

Allen Bradley Redundant System. - Redundant CPU, Network Module, Power Supply. Just replace the faulty unit with stopping the system. - I/O Module hot swap.

Page 15 of 29

PLC & I/O Module Troubleshooting (Cont)

How to troubleshoot the PLC & I/O Module 1. Using Individual PLC Module Indicator

- CPU

Page 16 of 29

PLC & I/O Module Troubleshooting (Cont)

Communication module

Page 17 of 29

PLC & I/O Module Troubleshooting (Cont)

I/O Module

Page 18 of 29

PLC & I/O Module Troubleshooting (Cont)

2. Using RS 5000 programming software

Page 19 of 29

SILICA ANLAYZER

Page 20 of 29

MMF MEDIA REPLACEMENT

1. 2. 3. 4. 5. 6. 7. Note: When enter the vessel internal, oxygen shall be measured and shall be more than18%. Temporary scaffold and platform should be prepared at top of the MMF for lifting up and pouring the media. If permanent platform is not provided. Filter media will be lifted up and poured into the MMF from the top manhole. Fill in Gravel (1st, 2nd &3rd layer) via side manhole slowly and protect strainers from damage. When 1 layer has been filled, make top surface level flat before filling next layer. Close the side manhole after Gravel Layer and fill in Coarse Garnet, Fine Garnet, Silica, Sand and Anthracite accordingly. Repeat Pressure Test after media charged and carrying leak check especially for Manhole. Fill the water into MMF from the top until the water level is higher than the Anthracite soaking about 24 hours.

Page 21 of 29

RO TROUBLE SHOOTING
1) Head Retaining Ring

Page 22 of 29

RO TROUBLE SHOOTING
2) Head Assembly will not release from shell

Page 23 of 29

RO TROUBLE SHOOTING
3) Seal Leakage i) Head Seal Leak ii) Permeate Port Seal Leak

Page 24 of 29

RO TROUBLE SHOOTING
4) Sudden Drop in Permeate Quality

Page 25 of 29

MBE RESIN REPLACEMENT

Resin replacement is recommended once per 2-3 years. 1. Please note that information provided herewith is only basic guideline for resin replacement, kindly consulting Organo Asia Sdn Bhd for detailed procedures. 2. Mixed Bed resin withdrawal from Mixed Bed Exchanger a) Remove all resins in the Mixed Bed Exchanger, supply Demin water to rinse out all remaining resins in the vessel. b) Confirm the volume of each resin to be filled. Cation resin:250 litres Amberjet 1500 H Anion resin: 700 litres Amberlite IRA402Cl c) Fill up the Mixed Bed Exchanger with Demin water until the water level reaches the middle of bottom sight glass. d) Open top manhole and fill the cation resin. e) Close the manhole. f) Keep the cation resin one night for soaking. Rinse the resin. g) Fill up the vessel by Demin water until middle of intermediate sight glass. h) Open top manhole and fill the anion resin. i) Close top manhole.

Page 26 of 29

MAINTENANCE of WASTE WATER TREATMENT PLANT

Page 27 of 29

MONITORING AND MAINTENANCE REQUIREMENT

Carry out routine check of Water Treatment Plant System. Record down Daily Performance Log Sheet for WTP System at least on bihourly basis. If any abnormality of performance is found, quickly identify the cause and rectify the problem. Conduct pH sensor cleaning (with pure water and/or diluted HCl) and calibration (with standard pH 4 and pH 7 buffer solution) at least one a week. Schedule check for equipment as per recommended in its individual INSTRUCTION MANUAL. Schedule check for measuring instruments as per recommended in its individual INSTRUCTION MANUAL. Conduct calibration of measuring instruments like suspended solids meter, flowmeter and etc once a year if applicable. Periodically inspect of piece of equipment devices. Repair and/or replace parts of piece of equipment immediately if abnormal sound, wear and tear is found. Periodically check air tubing of pneumatic valves if possible. If excess air leak from tubing, that pneumatic valve may out of order for openclose.
Page 28 of 29

MONITORING AND MAINTENANCE REQUIREMENT (cont)

Item Data collection Check Daily Procedure Record down Daily Performance Log Sheet for Raw Water Treatment. Check the status and opening condition of equipment and instruments form control panel. Control Panel Daily Visually check the PANEL display indication, local flow indicators and pressure indicators. Acknowledge any alarm signals and take the appropriate corrective action. Operation personnel should confirm that the automatic operation is done correctly. System Area Rotating Equipment Chemical consumption Calibrate instruments Sample analysis for water quality Lubricant requirement Daily Daily Daily Annually Monthly Proper housekeeping and clean up the spillage. Observe for abnormal noise, vibration, surface temperature, and lubricant level if necessary. Ensure the operating condition such like operating flow rate and discharge pressure as per design. Observe chemical tank level daily. Replenish chemical when necessary. Contact entire instrument supplier for calibration. Send the water sample to the laboratory for analysis Apply hydraulic oil or grease into the motor gearbox when oil level below the requirement level. Please refer to the individual equipment manual

Monthly

Page 29 of 29