NAPTIN Skills Programme

REPORT ON FIELD TRAINING OF THE NAPTIN NIGERIA GRADUATE
SKILLS DEVELOPMENT PROGRAMME (NGSDP)
By
VINCENT ANTHONY
NSGDP/938890
SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS

OF THE PROGRAMME
May 2014
ACKNOWLEDGEMENT
I will like to express my gratitude to staff of Egbin Power Plc., the Transmission Company of
Nigeria (Akangba Transmission) and Ikeja Electric (Oshodi Business Unit). Special thanks goes
to Unit Heads at the various technical departments at Egbin Power Plc. for their guidance and
advice.
ABSTRACT
This report gives details of knowledge acquired, activities, and work done during the field
posting to Egbin Power Plc (Egbin Power Plant) and the inter sub-sectorial training at Akangba
Transmission Station and Ikeja Electric (Oshodi Business Unit). Information presented are based
on personal experience, study, and interaction with personnel at the various work locations and
departments. A larger volume of this report accounts for activities and tasks at Egbin Power Plc.
as a longer period of the field training was spent at this location.
TABLE OF CONTENTS
CHAPTER
1
PAGE
INTRODUCTION...............1
1.1 Background of Egbin Power Plant...1
1.2 Main Systems and Equipment......................................................................................1
1.2.1 The Steam Generator..1
1.2.2 Steam Turbine2
1.2.3 Condensing and Feed-heating....3
1.2.4 The Cooling System...4
1.2.5 Fuel Unloading and Storage...4
1.2.6 Water Treatment and Demineralization.5
1.2.7 Condensate Polishing.....6
1.2.8 Power System.6
1.2.9 Compressed Air...6
1.2.10 Screen System...7
1.3 Egbin Power Plant Steam Cycle..7
2. PRODUCTION...........11
2.1 Overview of Production at Egbin Power Plc..11
2.2 Efficiency....11
2.3 Technical Operations.......11
2.4 Chemistry12
2.4.1 Production of Freshwater and Potable Water..13
2.4.2 Demineralization..14
2.5 Work done and Activities in Chemistry15

2.5.1 Oil test..15
2.5.2 Analyses of Water Samples.17
2.5.3 Activity: Question and Answer Session..18
2.6 Shift Operations19
2.6.1 Layout of Controls.19
2.6.2 Unit Control Board21
2.6.3 Common Service Panel.22
2.6.4 Fire-Fighting Panel........22
2.7 Work done and Activities in Operations.....23
2.7.1 Backwashing of CCCW Coolers...24
2.7.2 Line Tracing of Closed Circuit Cooling Water lines.24
2.7.3 Routine Checks and Tasks.25
3. MAINTENANCE....27
3.1 Overview of Maintenance at Egbin Power Plc....27
3.2 Boiler Maintenance Department..27
3.2.1 The Boiler Plant.28
3.2.2 Unit Heavy Fuel Oil System..31
3.2.3 Soot Blower.......32
3.2.4 Air and Gas System...33
3.3 Work done and Activities in Boiler Department34
3.3.1 Replacement of Burner Gun packing34
3.3.2 Replacement of Oil seal of Gas Air Heater Speed Reducer..35
3.3.3 Boiler Plant Patrols35

3.3.4 Activity: Identification of Pneumatic and Motorised Valves37
3.3.5 Activity: Observation of Floating of Boiler Drum Safety Valves.............39
3.3.6 Activity: Identification and Familiarisation of Boiler Vent Valves.......40
3.3.7 Routine Jobs...41
3.4 Turbine Maintenance Department................................42
3.4.1 The Turbine........................................................................................................43
3.4.2 The Turbine Lubricating System...44
3.4.3 Low Pressure (L.P) Feed Water System45
3.4.4 High Pressure (H.P) Feed Water System...47
3.5 Work Done and Activities in Turbine Department...48
3.5.1 Replacement of Unit-3 Hydrazine Injection Pump gland packing.....48
3.5.2 Removal of Unit-5 Sampling Cooler Inlet and Outlet Valves........49
3.5.3 Removal of Unit-1 CPP Caustic Inlet Valve......51
3.5.4 Assembly of Station Compressor D52
3.6 Electrical Maintenance Department.52
3.7 Work Done in Electrical Department.......53
3.7.1 Carbon Brush Maintenance.53
3.7.2 Removal of Gas Turbine Generator Lube oil pump A.C Motor... ..55
4
INTER SUB-SECTORIAL TRAINING.........58

4.1 Akangba Transmission.59
4.1.1 Electrical Maintenance Department59
4.1.2 Work Done in Electrical Maintenance Department...61
4.1.3 Lines Maintenance Department.....61

4.1.4 PC&M Maintenance Department..62
4.1.5 System Operations.63
4.2 Ikeja Electric63
4.3 Oshodi Business Unit..64
4.3.1 Protection Control and Metering (PC&M)65
4.3.2 Lines..65
4.3.3 Fitters.66
4.3.4 Cable Jointers68
5 CONCLUSION70
LIST OF FIGURES
FIG.
2.1
PAGE
Maintenance as a transformation process.....9
2.2 The maintenance management process10

2.3
Fault classification of outage hours per year ..12
2.4 Total outage hours per year...13

2.5 Variation of steam turbine units MTTR for each year.....15
2.6 Variation of steam turbine units availability for each year......16
2.7
Power plant Units MTBF for each year16

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REPORT ON FIELD TRAINING OF THE NAPTIN NIGERIA GRADUATE

SKILLS DEVELOPMENT PROGRAMME (NGSDP)

SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS

2.5 Work done and Activities in Chemistry15

3.3.3 Boiler Plant Patrols35

INTER SUB-SECTORIAL TRAINING.........58

4.1.3 Lines Maintenance Department.....61

2.2 The maintenance management process10

Fault classification of outage hours per year ..12

2.4 Total outage hours per year...13

Power plant Units MTBF for each year16

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