japan shut down maintenance training-pidah

7/29/2019 Japan Shut Down Maintenance Training-Pidah

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Presented by

Rafidah Binti Mohd SharkawiElectrical & Instrumentation Section


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2nd JulyGreeting to TMP, Si Dept. Revie Safety Education, Rule Explanation of TMP Staffroom,Greeting to SaiBouKyou, Training on the Site, Meeting to adjust the schedule, SeparateMeeting and Making the Daily Journal.

3rd July to 12th July

Morning Gathering, Training on the Site and Making the Daily Journal

13th July

Morning Gathering, Training on the Site, Making the Daily Journal and Meeting, Greeting

to SaiBouKyou, Cleaning the Staffroom and Greeting to TMP.

7th July

Sight-seeing at Hiroshima

8th July

Free time (Tanabata Festival)

Brief Summarized of the Japan SDM TrainingSchedule


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SE 1

SE 8

SE 3

SE 6

SE 7

SE 9

Tokuyama Corporation

Fumed Silica

Polysilicon


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SE 9

DCS Toshiba Ciemac Electrical room

Annubar flowmeter

RTD calibrator (Resistance Temperature Detector)

Bubbler level transmitter

Metal touch ball valve

C section drum pressure control

Thermocouple

Fire water

Training on the Site


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Safety check

Low voltage

VVVF (variable voltage variable frequency)

UPS (uninterrupted power supply C 1400)VESDA (very early smoke detector apparatus)

Haloon gas

SE 9 : Electrical Room


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Similar to a pitot tube used to measure the flow of gas or liquid ina pipe.

measures the difference between the static pressure and theflowing pressure of the media in the pipe.

The volumetric flow is calculated from that differenceusing Bernoullis principle and taking into account the pipe insidediameter.

The biggest difference between an annubar and a pitot tube is thatan annubar takes multiple samples across a section of a pipe. Inthis way, the annubar averages the differential pressuresencountered accounting for variations in flow across the section.

Annubar


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Sensors that are used to measure temperature bycorrelating the resistance of the RTD element withtemperature.

The element is usually quite fragile, so it is oftenplaced inside a sheathed probe to protect it.

Resistance thermometers use electrical resistance andrequire a power source to operate

RTD (Resistance Temperatures Detector)


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Bubbler Level Transmitter

Air supply Regulator Flow Indicator Bubbler LIT

Operates by supplying compressed air into a bubbler tube at aconstant rate with its opening placed near the bottom of the liquid.

Measures the pressure required to force air through the tube andgenerates a 4-20 mA signal which is proportional to the depth of theliquid.


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A type of flow meter that measures the velocity of a liquidor gas (fluid) by using the principle of ultrasound.

Using ultrasonic transducer, the flow meter can measurethe average velocity along the path of an emitted beam of

ultrasound, by averaging the difference in measuredtransit time between the pulses of ultrasound propagatinginto and against the direction of the flow.

Ultrasonic flow meters are affected by the temperature,density and viscosity of the flowing medium.

Ultrasonic Meter


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Metal Touch Ball Valve

Air will be supplied to line A where it will push theinstrument close. A signal will be send to DCS to informthat the valve is open. Air will be supplied out throughline B. This is to release the pressure on the other side of

the chamber. When there is a power break down, the air will besupplied to line B, where it will push the instrumentopen. Again, a signal will be send to DCS to inform thatthe valve is close.

Maintenance is done every year


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Fire Water

SE 9 Section A9 and B9 Fire water testing via control room


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Marshaling cabinet room

CS5 HCL waste pit 5E-2440 plat exchanger Silica plant dryer

SE 8


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Marshaling Cabinet Room


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Floor and metal frame are all in anti-acid coating.

For the bubbler, teflon tube is used as sheath.

CS5 HCL waste pit maintenance


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Open the coil to prevent the instrument fromdamage during mechanically maintenance.

Silica Plant Dryer


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DCS room Toshiba Ciemac cleaning of event

recorder

FCS and marshaling room using old version ofVESDA

A7

D7

BJ7

Etching room

SE 7


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Replacing Teflon membrane

A7


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Removal of filter


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D7


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It has excellent high temperature mechanical

properties.

Also has chemical corrosion resisting.High temperature oxidation resisting, wear-proof

capability and less specific weight.

Ceramic Ball Valve


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A magnetic field is applied to the metering tube,

which results in a potential difference proportional

to the flow velocity perpendicular to the flux lines. The physical principle at work is electromagnetic

induction.

Disadvantage : -can only measure conductive liquid.

Advantages : - as the liquid could go directlythrough, there is no pressure drop.

- sensor is not contact with liquid.

Magnetic Flowmeter


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Magnetic flowmeter after washing with HCL.


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Polishing of Belljar.

Cleaning machine part mitsubishi.

Dryer temperature yearly inspection

Cutting pure water washing dryer cooler checkinspection packing

Optical fiber sensor if there is nothing within therange of the sensor, the level value is high.

BJ 7 and Etching Room


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Finishing process

Ph calibration every month

SE 6


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Pure water chemical washing pure water washing heater/dryer cooler

Cleaning is done monthly.

Finishing Process


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HCL is used to clean and pure water is used to wash.

Early value is taken before calibration.

Buffer solution pH 7 is for zero adjustment.

Buffer solution pH 9 is for span adjustment.

Acidic side calibration range is 4 - 9.Alkali side calibration range is 7 9.

pH Calibration


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PH Calibration


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Electrical room

Ph calibration every month

SE 3


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Power supply of BJ 3.

One supply for two belljars different from TMSB.

Observed filament seeding and belljar cleaning.

Electrical Room


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Ph meter YokogawaYanaco COD (chemical O2 Demand)

Shimadzu TNPC (total nitrogen/phosphorous analyzer)

Ph calibration

Pump cleaning

WWT


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HCL is used to clean and pure water is used to wash.

Early value is taken before calibration.

Buffer solution pH 7 is for zero adjustment.

Buffer solution pH 9 is for span adjustment.

Acidic side calibration range is 4 - 9.Alkali side calibration range is 7 9.MLSS (mixed liquid suspended solids) to measure

the clearness of the water.

pH Calibration


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HCL is used to remove the scale.

The pump hose is stepped to remove the scale from

inside the hose.

Pump Cleaning


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Control valve maintenance

Assembling

Disassembling

Steam cleaning

Nitrogen dryer

Testing

Motoyama


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Observed the assembling, cleaning and checking

process for eccentric rotary valves (ceramic rotary

valves).Valve packing : yarn packing and v-packing (teflon)

Lapping compound to smoothen the seat.

Seat & Plug Touch check

Gasket lubrication is using demnum grease.

Seat leak test

Body test

Motoyama Workshop


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The stem will be sprayed and will be put inside the

seat.

If the color at the plug is smooth, then the seat isalright.

If not smooth, lapping compound is still needed.

Seat & Plug Touch check


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Is done to check whether the seat is smooth and even

that it can fit the plug.

Test value is calculated using :Air 2.434 *cv*(P1+1.0033)*1.01

P1=4kg/cm2G

Water 0.1428*cv*P1*leakage class

Seat leak test


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Body test is done to check whether the connection

between the bonnet flange and body flange is

correct.

Body test


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Lapping compound

Assembling process


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Body test check is in progress


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Field instrumentation YamaichiValve disassembling from actuator and valve body.

UV tube Pointer remover

Pressure gauge daily maintenance

PG calibration

Differential pressure calibrationVariable area flowmeter (rotameter)

Pyolan tape

Instrumentation Workshop


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Instrumentation Workshops Storage


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Pressure gauge calibration

Disassembling of control

valve


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Pressure gauge maintenance


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Pressure gauge lapping tool


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Variable area flowmeter

Use to remover float


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Pyolan tape

UV tube

Pressure GaugePointer remover

Numbe

r Colors

Width

[mm,(in)]

Length

[m,(yd)]

Thickness

[mm]

Adhesive

Strength

[N/25mm]Holding

Power

[mm,40 ]Tensile

Strength

[N/50mm]Elongatio

n

[%]K-10

srs.

CL, WH,

BE,

YE, GR,

BL,

RE

25,50

(1",2")50

(55yd) 0.16 10 0.1 300 8


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Study about variety type of gaskets 6503A

6500A

6503

8596V

7596V

N7030

Glass fiber gasket

7010

7020

Special gasket

Rubber gasket


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Lif i J ( T k )


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Sightseeing in Hiroshima

Life in Japan ( Two weeks)


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Food


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Food


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Thank you

END

japan shut down maintenance training-pidah

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