Introduction to Coal Fired Power Plant

From a coal stockyard, coal will send to mill bowl through the coal bunker before it goes to boiler to heat water to the superheated steam. The superheated steam at the correct temperature and pressure flows into a turbine which spins a generator to produce the electricity before introducing to the transmission line. The bled steam is cooled, condensed back into water and it will return to the boiler to start the same process over. The following image illustrate the general process how coal fired power plant generate or produce the electricity.

Image credit

Related previous article that you may read;
- Boiler Function Block Generally
- Turbine Function Block Generally

Arizona to Get Large Solar Power Plant

Currently it is in planning stage for Spanish company to build the largest solar power plant in Arizona. The operational of the Arizona solar power plant will produce 280 Megawatt solar energy and the plant will sell around $4 billion in clean electricity over 30 years.

Arizona Solar Power Plant in Project Planning Stage

The solar plant located is 70 miles of Phoenix, near Gila Bend Arizona scheduled to be operate in 2011. If the solar plant energy is approved, it will be the largest solar power plant in the world and the construction could be begin as early as next year.

My Handphone - Nokia 2100

Currently I use this handphone on daily basis. It is already one year I used this Nokia 2100. Even this handphone is cheap and very simple compared which existing in the market with various function and latest technology, my Nokia 2100 gave me no problem at all since I bought it last year.

Nokia 2100 Specification
- Monochrome Graphic
- Monophonic
- Phonebook 100
- Standard Li-on 720Ah Battery

I am sure most of my colleagues already change their own hanphone with the sophisticated and the latest technology. Camera, GPRS, 3G, polyphonic, great audio and etc. Me? I might thinking of it but at the same time I will not spend unwisely just to get a new one. Haha... In the future post, I will consider to write about the latest technology handphone which can be reviewed by my readers. Enjoy!

Beautiful Night Scene at Coal Fired Power Plant

I found this photo in flickr. This coal fired power plant night scene is very beautiful.

Three chimneys or stacks photo shot with good angle and the color is beautiful. The reflections are great. Do you know where it is located? Or it just an illustration. Never mind, anyway it is a nice pic!

Digital Temperature Transmitter

At first in my previous post I think this instrumentation device is called temperature or RTD's converter. But when I surfed the internet about this equipment, it's name 'Digital Temperature Transmitter'. Currently used at Turbine Generator area and some areas in power plant.

Digital Temperature Transmitter

Application
- Machinery, Plant Construction
- Process Industry

Special Features
- Universal via Window PC
- Isolation voltage 1500VAC between sensor and current loop
- Signalling configurable for sensor burnout and sensor short circuiting

Designation of terminal connectors

Connection of Programming Unit PU348


Accessories

On the accessories, I found that there is one configuration software which need to be ordered separetely by enduser. My specification required for this instrumentation device is;

Pt100 3/L/f
DC 9....36V
4 to 20 mA
0.... 160 degree C

How to order? If this device need to be configured first, we need also the software configurator.

More details, you can visit WIKA website.

Hydroponic pH Meter Application

I stumbled upon this hydroponic pH meter which is widely used in agriculture industry. Just for sharing among my readers this instrumentation test equipment is very important especially in water content analysis.

Hydroponic Deep Water System

Hydroponic relatively low maintenance and highly very efficient.

Hydroponic pH Meter

Monitoring the level of pH is quite essential. When the pH is not at the proper level the plant will lose it's ability to absorb some of the essential elements required for healthy growth. Most of the plants will growth in acid environment 6.0 to 6.5 pH event the pH level is vary from plant to plant.

Related article you may interest:
1) Purpose of the Water Analyser System in Coal Fired Power Plant
2) Portable pH Calibrator

Heat Exchanger

Heat Exchanger is a package equipment built for efficient heat transfer from one medium to another medium. Car radiator is one common example of heat exchanger which hot engine-cooling fluid transfer heat into air flowing through the radiator.

Heat Exchanger is widely used in space heating, refrigeration, air conditioning, power plant, chemical plant, petroleum refinery and natural gas processing.


This is the common view of heat exchanger in my power plant. Only the color is different. Just want to match with common color in this weblog. Haha...

Nature of Fluid Flow Through The Plate Heat Exchanger

A plate heat exchanger is a type of heat exchanger that uses metal plates to transfer heat between two fluids. The idea behind this concept of a heat exchanger is the use of pipes or other containment vessels to heat or cool one fluid by transferring heat between it and another fluid.

Turbine Function Block Generally

This is another turbine function block which also contributed by my colleague as in my previous post.

Hopefully you can learn something on this big picture generally either on the turbine side or the boiler side. Happy learning!

Boiler Functional Block Generally

This function block actually draw and has been contributed one of my best friends when he worked with me a few years ago in our power plant.

He is very hardworking and one of the best staff in instrumentation department. Thanks my friend.

The Fancy Color of Beamex MC5 Fieldbus Calibrator

Beamex MC5 Calibrator is one of the important of our instrumentation test equipments in power plant or specifically instrumentation's workshop. The MC5 Fieldbus Calibrator is a combination of a multifunction calibrator and fieldbus configurator. Below is the description and main features of the MC5 Fieldbus Calibrator from Beamex website.

"Introducing the world’s first fieldbus calibrator

The MC5 Fieldbus Calibrator is a combination of a multifunction calibrator and a fieldbus configurator. The MC5 is a compact, easy-to-use and field compatible calibration solution that offers a lot of functionality. The fieldbus functionality of MC5 includes reading the digital output of the fieldbus transmitter, changing the configurations of transmitters and transmitter trimming. Calibrating fieldbus transmitters with the MC5 requires only one person and the calibration results are automatically documented.

Main features:

• Calibrate Foundation Fieldbus H1 or Profibus PA transmitters
• The MC5 is a calibrator and a fieldbus configurator in one unit
• The MC5 makes traceable calibrations
• Calibration results are automatically documented in the MC5
• A compact, easy-to-use and field compatible calibration solution
• The MC5 Fieldbus Calibrator can be used for various other calibrations as well

The photo that you see above is a common color that available in the market. But have you seen the pink color of Beamex MC5 Calibrator before?"

I am sure you never see this color before. But I am not sure whether this fancy color is in the market or not. Try to contact your supplier to know more about this. Mmmm...

Portable pH Calibrator

I am just surfing the internet to find a good thing on our instrumentation device. Then I found this one of the ABB products. Portable pH Calibrator is using to simulate variable pH and also can be as pH analyzer and calibrator. It is extremely useful for grab sample pH measurement as well as bench setup and field calibration or troubleshooting of process pH analyzers.

Model TB100 Portable pH Analyzer/Calibrator

When it comes to deal with process pH instrumentation, I personally thinking that this kind of calibrator is very essential and very good to have one. Very easy to use and the result can be much better. I am not sure how much it will cost. But you will save a lot of money when you can cut your cost to purchase buffer solution to do monthly calibration.

Chernobyl Nuclear Power Plant Disaster

Have you ever heard this Chernobyl disaster before? Chernobyl disaster or simply popular with name 'Chernobyl' as a result of a flawed reactor design and was operated inadequately trained personal. Happened in Ukraine near the town of Pripyat, 26th April 1986.

Chernobyl was the worst accident nuclear power plant in history with 28 dies within 4 months from radiation or thermal burns; 19 have subsequently died, and there have been around nine deaths from thyroid cancer apparently due to the accident: total 56 fatalities as of 2004.

Reactor Diagram

The Effects of The Chernobyl Disaster;

- International spread of radioactivity
- Radioactive release
- Health of plant workers
- Residual radioactivity in the environment

The damaged Chernobyl unit 4 reactor building

Today Chernobyl After Disaster;

- The need for future repairs
- The lava (or fuel containing materials FCM)
- Degradation of the lava
- Possible consequences of further collapse of the Sarcophagus
- Grass and forest fires

For more details about this nuclear power plant you can check at the Wikepedia and this World Nuclear Association.

NEW Canon Digital Camera IXUS 960

Are you interested in owning a digital camera? Yesterday, I window-shopped several supermarket in a city. My eyes focused on this small and cute digital camera in one of the showcases.

Specifications:
- 12.1 Mega Pixels
- 3.7 Optical Zoom
- 2.5" LCD Display Pure Color
- ISO 1600
- Optical Image Stabilizer
- Multi-face Detection
- Crystal Clear Image
- Titanium Casing
- High Speed USB 2.0 Rate Connectivity
- Optional Accessories: Water Proof Casing WP-DC19
- Retail Price: RM1699/=

At the moment, I just survey around and hopefully will get a good one soon. Even though we also in charge of the purchasing like computer, camera, printers and other IT goods or related instrumentation field device, but this is for my personal used and not for my work at office or power plant.

Trial Instrumentation Field Device ECP Flow Switch Chlorine Application Failed

Again, this morning operation raised defect to us on Electro Chlorination Plant (ECP) flow switch problem. After a few days switch has been installed with minor modification on the probe; new spring changed to stainless steel and the flapper is coated with anti-oxide hoping that the lifetime can be longer than before, but the result frustrated. There is already a few times I mentioned in this blog that the unreliable flow switch urgently needs to be replaced as the ECP Cell downtime very frequently happened.

Recently, Vega and Endress Hauser tested their probes on the ultrasonic type. It took one week to complete in January. The tuning of the parameters has been done for a few times to get a good result but at the last stage it failed. The reason it failed is the flow rate is not stable due to two medium mixture, water and air bubbles. In this case, air bubbles will absorb the signal from the ultrasonic then cause the reading fluctuating. At the end, they would like to trial another type of measurement either magnetic or different pressure DP type. But I am still waiting for them to their recommendation which has been promised in February.

I still remember that the current Flotech flow switch that we are using already more than two years. But recently in these 3 to 4 months, the flow switch flapper and the spring brittles and easily broken. Actually this is not the first time we change to a new brand on ECP flow switch. If I am not mistaken, it is already third or fourth times since 2004. So far most of our instrumentation field devices when comes to a new solution doesn’t give us much trouble. Aaarrrgghh… meaning that I have to find out other new brand or new type of flow switch to cut this problem from happens and happens again.

At this moment, I have to contact various manufacturers to recommend the suitable flow switch on the chlorine application which urgently required including ABB, UE and Kelco. Since the stocks balances at the store for the old type (Flotech) are very critical low therefore we need to reorder for temporary used.

Valentine's Day 14 February

When it comes to 14^th February each year, candy, flowers, cards and gifts are exchanged between loved ones. Why they celebrate this event especially the young people? For those interested to know more about this Valentine’s Day, you can visit this website.

Me? I am not interested to celebrate this event. Everyday you can show love and caring to your couples. Why people wait this event to show and express their love? And people who are too excited will spend so much money. Whatever la, happy getting angry when your lover not wishing you this Valentine’s Day. And also happy crying when no one sends you any roses. Haha….

I am just coming back from Chinese New Year holiday. I will update this blog soon. Thanks for reading my weblog.

Gong Xi Fa Cai and Happy Chinese New Year!

Tomorrow is Chinese New Year and I wish you all who celebrate this festival Gong Xi Fa Cai! February 07, 2008 will mark the beginning of the Rat year and year 4705 of the Chinese calendar.

Meaning that I'll be on leave and going back to my hometown by tomorrow morning. I will take about 7 days o leave therefore this blog also will not updated during this period. For those who are plan to travel or going to hometown I just wanna say 'always drive safe and have a nice trips!'.

Endress Hauser Cerabar M PMP48

The Cerabar M PMP48 pressure transmitter measure gauge pressure at tank gauging Demin Plant. It's time to reorder the spare since the stock level at our store is low.

For more details, you can visit Endress Hauser website.

New Pressure Gauge to be Fitted at The Condenser Inlet Pipe

The reason to fit the pressure gauge is to investigate the Cooling Water Pump problem and condenser performance. On each inlet and outlet leg there are stubs fitted with isolating valves and blank flange. Isolate, remove flange and drill and thread to suit pressure gauges. (Note one inlet leg has no isolating valve) Suggest gauges have to be as fitted on CW discharges i.e. SS 150MM dia, range 0 to 6 bar. See attached Photos.


On the outlet sides propose to fit gauges at lower level to make reading easier by piping impulse line down to suitable mounting location.

Power-Gen Asia Conference and Exhibition 21-23 October 2008

I am just surfing the internet today and found this great event which will be organized as follow;

Event: 16th Power-Gen Asia Conference and Exhibition 2008
Date: 21 - 23 October 2008
Venue: Kuala Lumpur Convention Centre, Malaysia

For those who are involve in power generation would be much benefited from this such event which primarily to contribute and develop power energy in this region. More details you can go straight to this website.

The 15th Power-Gen Asia 2007 event was successfully held at Bangkok, Thailand.

I am very interested to participate in this event so that I can gain more knowledges and can contribute to others. Hopefully on this October 2008. Mmmmm....

Blog Summary On instrumentations.blogspot.com January 31, 2008

The first month of January 2008 had just passed. At the end of each month, I need to submit my report to my immediate supervisor. There is an official format report must be follow. I am not going to put all of my monthly reports here. But just put the summary report on this Instrumentation and Process Control blog so that you can make quick review what was happened in our Coal Fired Power Plant January 2008. This summary report does not mean the actual report for the month because some confidential parts cannot be revealed. The following list is my entry post for the entire month of January;

1. Manjung Coal Fired 3X700 MW Power Plant on Project Description
2. Electro Chlorination Plant Flow Switch Problem
3. Proposal of New Waltron Sodium Analyser 9001 Series at Water Treatment Plant
4. Purpose of Water Quality Analyser System in Power Plant
5. Generator Stator Vibration Spikes
   
6. Feed Water Tank Differential Pressure Gauge Unit and Range Change
7. Microrec Problem
8. Bunker Level Transmitter Faulty
9. Washdown Water Sump Level Switch Problem
10. Band Screen Guide Radar and Hydrostatic Level Transmitter
11. Generator Panel Alarm on Conductivity Analyser
12. Electro Chlorination Plant New Flow Switch Project
13. Water Treatment Plant Acid Day Tank Magnetic Level Switch Faulty
14. ABB Water Analyser New Purchasing List
15. Coal Bunker Level Transmitter Problem
16. Generator RTDs Converter To Purchase: Brand WIKA
17. GP Joran Coal Fired Power Plant January 2008
18. LP Heater 4 Normal Level Control Valve Diaphragm Leak
    
19. Lumut Power Plant
    
20. Steam Turbine
    
21. Generator Hydrogen Gas Cooling System
    

All things that happened which I think can be put in this blog on daily work basis still continue. My blog Instrumentation and Process Control also will doing summary report on continuing monthly basis at the end or early month so that my blog readers will not miss it. Enjoy this reading!

Unit No.1 High Pressure Heater No.6, 7 and 8 Emergency Control Valve Not Fully Shut

HP HTR 8 level transmitter showing very low reading. Check at local gauge glass found actual level low. Check at the emergency control valve found, High Pressure Heater No.7 and No.8 valve position not fully shut and causing the HP HTR level drain to the flash box. DCS command to the control valve already fully shut. Suspect not enough air pressure to close the control valve (air to close).

After doing some checking, not enough air pressure to close the control valve from the volume booster. The function of volume booster is to boost big volume air to the valve diaphragm either fast closing or fast opening. Servicing done for all volume booster HP Heater and reading back to normal operation.

Checking at the store found that the stock level for this volume booster is also low and need to raise new purchase request. I enclose here the photo and the specification for you to review.


Volume Booster
Blackborough Control Valve
Model No : 25
SWP : 150 Psig
Pipe Conns : ¼ ” NPT