ACKNOWLEDGEMENT

First of all, I would like to say Alhamdulillah, for giving me the strength and health to
do this industrial training.

I would like to say thank you very much to Tanjung Bin Power station, for giving me
the opportunity to work with their employees and gain as much experience throughout the
Industrial Internship Program.

I am heartily thankful to En Yazid bin Sulaiman for having the trust and faith in
accepting me to be a trainee under his section. I would also like to thank my direct
supervisor, En. Azlan bin Mohd, whose encouragement, guidance and support from the
initial to the final level enabled me to develop an understanding of the plant in TBPS.

Not forgotten to other staff in the section, En. Mohd Shafid Rahmat, En Azizul bin
Mukmin and Mohammad Nazry bin Ithnin for all their help and support. Besides that, I would
like to thank all the staff in water and waste water treatment plant for sharing knowledge and
experiences during my industrial training.

Not to forget, my friends who were doing this internship with me and sharing our
ideas. They were helpful that when we combined and discussed together.

Lastly, I offer my regards and blessings to all of those who supported me in any
aspect during the completion of the internship programmed.
ABSTRACT

I had completed my 3 months training at Tanjung Bin Power Plant, Serkat, Johor from
1st of December 2014 until 28th of February 2015. Briefly, Tanjung Bin Power Plants owner
was Malakoff Corporation Berhad. Malakoff was a very stable, successful and renowned
company because it had several project aggressively expand in middle east such as Saudi
Arabia, Algeria, Oman and Jordan. Besides, this coal fire type power plant was announced
as the biggest plant in south east asia. Malakoff also had won the Best Emission Reduction
Project in Asia award in the prestigious 2006 Power Asian Ceremony. It because Malakoff
used latest clean emission technologies such as electrostatic precipitator (ESP) and flue gas
desulfurization (FGD). My objective in industrial training programme was to gain much more
knowledge about the plant and all the process involved. Hence, I also can gain experiences
while working and saw my job scope within my field of study. At first day of my internship
programme, I was report under the supervision of Encik Azlan bin Mohd, a section head in
Chemical and Environment department, and I was placed in the lab water and coal analysis
room. I have been exposed a lot on the laboratory work and getting chances to handle a lot
of new instruments related to chemistry field during my training period. In the beginning of
my training, I was given a task to study about the analysis of water and coal sample that
been taken from different part of the plant to monitor its parameter, the process of
demineralized water production from tap water, the process of waste management, the
process of sodium hypochlorite production from seawater and the environment parameters
that are related such as stack emission monitoring. Apart from that, I was also asked to
conduct some quality on samples taken from the plants at condenser extraction pump, boiler
drum, main steam, de aerator and economizer. To get these samples, I was brought inside
the plant and took the samples at the feed water sampling rack for water samples. At the
sampling rack, there are pH, specific conductivity, cation conductivity, dissolved oxygen
analyzers. These analyzers were used to confirm the result collected from the quality tests
done inside the laboratory. In the middle of my training, I did a lot of experiment on pH
measurement using pH meter, specific conductivity measurement using conductivity meter,
phosphate, chloride, and silica content by using spectrophotometer. Besides all those
learning process, I also learned to improve my communication skills by communicating with
all the staff of Tanjung Bin Power Plant. As the conclusion, the three months training period
was very helpful to have a better understanding of what we have learned theoretically in
class, not to forget it also prepare us for our future real working life.
INTRODUCTION

Malakoff Berhad was incorporated on 9 October 1975 as a plantation-based

company. It was listed on the Main Board of the Kuala Lumpur Stock Exchange (currently
known as Bursa Malaysia) in 1976. A shift in its corporate direction resulted in the disposal of
its plantation-based assets in October 1993 and the subsequent venture into the power
sector.In 2007, Malakoff Berhad was taken private by MMC Corporation Berhad and
subsequently known today as Malakoff Corporation Berhad (MCB).Committe to
sustainability, we hold the health, safety and security of our staff paramount. We take great
care to minimize the impact on the environments in which we operate and as a responsible
corporate citizen, we set out to be a good neighbour in whatever we do and wherever we go.
At present, Malakoff is the leading Independent Power Producer (IPP) in Malaysia
with an effective capacity of 5,350 MW comprising of 6 power plants that run on oil, coal and
gas. On the international front, as an independent water and power producer (IWPP), we
own a net capacity of approximately 690 MW of power production and 444,500 m3/day of
water desalination. Our overseas projects are located in Bahrain, Saudi Arabia, Algeria,
Australia and Oman. . In overseas, we work with local partners and/or developers as project
sponsors of reputable international power and water projects, and/or stakeholders in
consortiums.Malakoffs power generation and water desalination assets are held through a
number of subsidiary and associate companies located in Malaysia and abroad.
We aim to expand our power and water capacity in international markets through strategic
acquisitions of attractive assets.
Malakoff also provides project management services for in-house and external
projects through its wholly-owned subsidiary Malakoff Engineering Sdn Bhd ("MESB").
MESB was the project manager of GB3 Power Plant, Lumut Power Plants 500kV
Transmission Line Project (helicopter erection), 275kV Submarine Cable (Juru-Bayan
Lepas), TV3 Complex, Co-Generation Plant for Malaysian Newsprint Industries, Lekir
Coastal Development (a site reclamation project), Centralised Chilled Water Plant and
Electricity Distribution System within KL Sentral. MESB also played a key role in the
development of Tanjung Bin Power Plant.
INDUSTRIAL TRAINING PROGRAMME

2.1 Summary of duties

Week Activity
Report to Tanjung bin Power Plant admin
Week 1 building and attached under training
department.
Specifically attach under Chemical and
Environment department. Go to sampling
Week 2
rack and analyser room.
Week 3 Method use in water chemical analysis
Week 4 Analysis of water steam cycle chemistry
Week 5 Analysis of water from different location of
plant
Tour trip to plant site.
Week 6
Week 7 Coal and fly ash analysis
Week 8 Determination of sulphur content in coal
Week 9 Environmental monitoring
Study the process involved in electro
Week 10 chlorination plant
Study the process involved in water
Week 11 treatment plant
Study the process involved in waste water
Week 12 treatment plant.

2.1.1 Activity involved during Internship Programme

2.1.1.1 Report to Tanjung Bin admin building and attach to training department

At 1st December 2014, I was officially reported myself to Tanjung Bin Power Plant on
8.00 am in the morning. Tanjung Bin staff from training department, Cik Noraini
Mahamud was welcoming me and other practical students to Malakoff Tanjung Bin
Power Plant. I was attached into training department for 1 week and was given some
general information about this plant by our trainee. I was been introduced about the
overview of the plant and make the pass card that act as the punch card, hence I
was successfully become the Malakoff staff as a practical student.

Plant Overview Process

Generally, this plant purpose was to generate electricity by using pulverised coal as
main fuel to boil water in tube, thus evaporate it as steam and been through turbine
and connected to generator and produce electric for house and industry in Pontian.
Figure above was the summary of the process involved in plant from its raw material,
coal into electric. Actually, Malakoff has a deal with Tenaga Nasional Berhad (TNB)
where TNB was bought electric from our plant and in exchange TNB was the one
who decide how many Watt of electric must be produced by Malakoff to be
compatible in national grid system. Malakoff had 3 units of boiler and other machine
that each unit produce 700mw. So, this plant produced 2100mw per day and sold it to
TNB.

Now, I will explain the plant overview process from start of unloaded coal from ship
until it transform into electrical energy. At first, coal was been imported from various
countries such as Indonesia, Africa, Australia and Hong Kong. There were 2 types of
coal that were used in this plant such as the A grade one, bituminous coal and B+
grade, sub-bituminous. We not fully used bituminous as our main coal because the
cost is quite high. So, we use it both then, we blend it and give specifically ratio to
give efficient combustion rather than one type coal firing only. We used Coal
Unloaded Load (CUL) machine to unloaded coal from ship to coal stock pile.

Coal Unloader Load (CUL) Coal Unloader Load (CUL)

From stock pile, we used Grab Unloaded Load (GUL) machine to unload the coal
from coal stockpile to coal conveyor. Then, from here coal will transport via conveyor
to coal crusher house through junction tower before it reaches final destination, coal
pulverise mill where the coal was pulverise before its put into the furnace as main
fuel. The coal must be crush into small pieces because to make the combustion in
boiler more efficient. Coal was crushed into smaller volume in coal crusher house by
using grinder. Average coal size must between 50-100mm after it been crushed. Coal
which has high volume and density that couldnt be crushed were placed as waste in
ash pond. Coal conveyor had a roof that prevents excess of rain water applied on our
coal. In coal bunker, we have a tripper car that used to take different type of coal and
blend it into the coal feeder. Example of coal mixing by using ratio was MSJ and
Kayan 70:30. This coal mixing will give efficiency for combustion in boiler. After that,
these blend coal will travel to pulverise mill. Purpose of the pulverise mill was to
pulverise or grind the coal into very small particle like dust. In this mill, it have big
roller ball like that crush the coal into tiny pieces and transport it to the burner. In mill,
it has primary air fan that sucked air from surrounding and go through the
Regenerative Air Heater (RAPH) where RAPH function was to exchange the heat
changer from cold air to hot air. So, cold air from surrounding was been applied to hot
blade in RAPH thus, the heat exchanger process was involved between the air and
the blade hence, it produce hot air that to be transport to mill. Hot air must be
transport to the mill because to minimize the amount of moisture content in the mill.
Combustion would not efficient if total moisture in coal was high.

Coal Bunker Coal Feeder

Mill Roller Mill Roller size

After been crushed into tiny particles, this coal was sent to the burner in the furnace
to ignite fire. To start up the flame in furnace, we used light fuel oil (LFO) as a starting
fuel to ignite the fire. It almost impossible if we use coal only as start up fuel because
coal itself cannot produce fire. Thats why we use LFO and some spark of fire to start
up the combustion. After the combustion was stable then, we used the pulverised
coal as a main fuel of the combustion in boiler. In boiler, it has very high pressure and
temperature in it. In this plant, its boiler condition was sub-critical heat whereby its
boiler drum contained water and steam. Meanwhile, if the boiler condition was in
supercritical heat, it doesnt have a boiler drum because 100% water will evaporate
into steam. Boiler purpose was to heat the water inside the tubes by using pulverised
coal as a main fuel and convert it into steam by using evaporation process. Water
particle will expand when heat been applied and convert to gas state called steam.
Water that we used in tubes was demineralized water. This water was pure compare
to tap water because it contains only H2O molecule in it. All the impurities in it was
been removed by certain process in water treatment plant (WTP). This water must be
low in O2 to minimize the probability of corrosion in tubing. If the corrosion occur, the
tube maybe crack and overheat due to certain chemical reactions. The demineralized
water in tube was heat in primary super heater to convert it into steam. After that, the
steam will go to the first turbine that was HP turbine. Then, this steam will go back to
boiler and reheat back because the energy in steam was been used fully in HP
turbine to rotate it. This weak steam was reheat in boiler to increase their energy to
pass through the IPT turbine and LPT turbine. The turbine contains many shaft and
blade that rotate when the steam pass through it. So, if the generation of steam was
efficient, thus the blade and shaft in turbine will rotate more rapidly hence, it produce
greater power in electricity.

In this plant, it cycle system to minimize the waste that been produced. In order to
achieve that, Malakoff have one big condenser to convert steam back to water.
Whereas the water can use as make up water in boiler to produce steam. In
condenser, it used sea water as a cooling medium. Sea water was put into the tube
and it was pass through in and out of the condenser. This system was called Main
Cooling Water (MCW) in our plant. The sea water coding pipe was green in colour.
Originally, this seawater was from Electro Chlorination Plant (ECP) where the
seawater was injected by Naocl to prevent bio fouling in plant system. ECP was used
to kill any microorganism and organic material that could possibly corrode our MCW
piping in condenser.

Meanwhile in boiler, the coal that had been burned by fire was called flue gas. This
flue gas contain high chemically toxic such as NO x and sulphur that could harm any
organisms whose inhale it. So, Malakoff decided to use latest emission technologies
to control air pollution that were Electrostatic Precipitator (ESP) and Flue Gas
Desulphurization (FGD). First, this flue gas will pass through the RAPH where the
heat was exchanged between air and blade to convert it into hot air. Flue gas was
sucked by giant fan called Induced Draught Fan (IDF) to make it flow faster to ESP.
At ESP, the flue gas was charged by electrolyser to make it the particles charged
positive and negative. The flue gas then will trapped between the metal plate and
been collected by using hopper before transport it to silo. This product was originally
 come from flue gas was called fly ash. In ESP, there were 2 output products, there
were fly ash and clean flue gas. Fly ash was ash that been trapped by ESP from flue
gas. This fly ash can be considered as waste but in Tanjung Bin, we used this fly ash
to sold them at Lafarge company whereas fly ash was used as raw material in
cement production. After that, the clean flue gas was transport to FGD for further
cleaning before it emit as more clean gas by chimney. ESP has the same concept as
a vacuum cleaner. The dust from flue gas was trapped by ESP and it produces fly
ash and clean flue gas. Actually, ESP was categorized one of the machine that
control air pollution. In Tanjung Bin power Plant, we used FGD and ESP as our air
pollution control device. In other words, we have a double protection and produce
more clean air to environment.

Finally, the flue gas was arrived its final destination that was FGD. FGD was used to
minimize the NOx, sulphur and carbon monoxide that could be harm for environment.
Basically, it used only sea water to remove the harmful substances. Sea water was
spray through the flue gas that will result sulphur and other chemical reacted with sea
water and the molecules become heavier. So, the heavier harmful molecule was drop
down into aeration basin to introduced O 2 in it. Meanwhile the clean flue gas will go
upwards. This cold type gas didnt have enough energy to make it to the high
chimney because it particles were not active. So, we used hot aired steam to
increase the temperature of the clean gas to give sufficient energy to make it up to
the chimney. Then, the clean gas was emitted by chimney.

2.1.1.2 Specifically attach under Chemical and Environment department

On 8/12/2014, I was sent to Chemical and Environment (C&E) department to study

further more about this plant that related to chemistry. Meanwhile, the other practical
students also went to different department according to their course. On first day, at
8.30 am in the morning, I was went to my supervisor room, En Azlan bin Mohd to
have a briefing with other Malakoff staff in admin building. This department consist
one section head that was En Azlan, 2 chemical engineers, Nooradibah musa and
Aizuddin, and other lab technicians whose working on the lab. Actually, Section head
and the engineers were working at admin building while the others lab technicians
were working on lab. They were working in separate building, but in the morning
breefing, the lab technicians must be gather around at section head office to give any
update and report about issues or recommendation about this plant.

In my first day, I was introduced myself to Malakoff staff while in morning meeting
about myself. I told that I come from Pontian and studied at Uitm Arau, Perlis and
take Diploma in Industrial Chemistry. All the staff quite happy and cherish after they
know a practical student have an internship programme in this department. I admitted
it they were all very easy going, nice, helpful, and continuously support and teaches
me about this plant.

After morning briefing, my lab technicians, En Shafid bin Rahmat and I went to
sampling rack and analyser room at the plant site. We were wearing Personal
Protective Equipment (PPE) such as, working jacket, safety helmet and safety boot
to prevent any hazard that could harm us. Sampling rack and analysers contain
many piping that were used to get water sample from different location of plant.
Examples were boiler drum, main steam, economizer, condensate extraction pump,
deaerator and many more. The water sample that were about to analyse in lab was
actually taken from here. This room also have many analysers to monitor the
parameters such as temperature, pH, specific conductivity, cation conductivity,
dissolved oxygen and sodium. These parameters can indicate certain condition in
plant. For instance, sodium parameter was set to monitor any leakage of sea water in
condenser. So, if sea water ingress in condenser, sodium reading in sampling rack
will high. Actually, sodium parameter was not the only one could monitor the sea
water ingress, but it also must tally with specific conductivity and cation conductivity.
These, conductivity also increase if sea water ingress in condenser because sea
water have high amount of positive charge and minerals such as sodium. It also can
generate electric pretty well. Definition of conductivity was an ability to conduct any
electricity.
 Sampling rack and analysers

My technician, En Shafid was teaching me about chemical dosing process in this

plant. Chemical dosing was one of the method or step uses in water treatment process to
enhance boiler efficiency. The general purposes of chemical dosing were to maintain boiler
operation and enhance performance of the equipment. In Tanjung Bin Power Plant, boiler
house was heart of the plant. Boiler plays an important role to give a better output towards
the system. Boiler was also sensitive towards any change of physical or chemical properties
because its condition was in sub-critical. Whereas the temperature also pressure were very
high in boiler. In that case, any slightly changes in parameter will cause any malfunction that
could be a greater loss for our output. Thats why chemical dosing was used to extend its life
cycle. It also to improve the overall production of facility as it pertains to water treatment.
There were certain specific purposes of the chemical dosing such as :

To prevent corrosion and scaling of the feed-water system and protect against
corrosion in the steam-condensate systems.

To react with any feed-water hardness and prevent it from precipitating on the boiler
metal as scale.

To condition any suspended matter such as hardness sludge or iron oxide in the
boiler and make it non-adherent to the boiler metal.

To eliminate oxygen from the water and provide enough alkalinity to prevent boiler
corrosion.
 In chemical dosing, there were 3 types of chemical used that to be injected at different
locations of the plant. There were ammonia, phosphate and hydrazine. Below is the
summary of chemical dosing in Tanjung Bin Power Plant.

Chemical Sodium Phosphate Ammonia (NH4OH) Hydrazine (N2H4.H2O)

(Na2.6H0.4PO4.12H2O)

Concentration 2% 12.5% 1%

Purpose Sedimentation of Feedwater pH control Removal of dissolved

scale and pH control oxygen

Condensate Condensate
pump outlet pump outlet
De aerator De aerator
inlet outlet
Injection Point Boiler drum Make up water Make up water
pump outlet pump outlet

Pressur Norma 185.6 barg 20 barg 20 barg

e at l
injection
Max 210 barg 34 barg 34 barg
point

Intermittent initiate
by operator, auto
Mode of operation Continuous Continuous
stop after 30 mins

Manually start, Automatically control Automatically control

automatically stop based on feedwater based on feedwater
Control
by timer flowrate and pH flowrate and DO

In addition, this plant also has monitored their water chemistry. This water chemistry
includes parameters such as pH, chloride, silica and many more. Different location of the
plant has different type of parameters. These were the purpose of the monitoring water
chemistry:

To prevent equipment damage due to malfunction of water chemistry related

equipment
To determine the chemical transport characteristics of the cycle, make final selection
of water treatment approach, and establish water and steam chemistry limits
To assess major sources of impurities and corrosion

These water chemistry contains different type of parameters at specific location of plant. If
any of the parameters were out of spec, action levels was required to get it back to normal
level again in shortest time. It has certain type of action levels for example:

Normal - Values are consistent with long term system reliability. A safety margin has
been provided to avoid concentration of contaminants at surfaces and under deposits

Action Level 1- There is a potential for the accumulation of contaminants and

corrosion. Return values to normal levels within 1 week.

Action level 2 - The accumulation of impurities and corrosion will occur. Return
values to normal levels within 24 hours.

Action Level 3 - Experience indicated that rapid corrosion could occur, which can be
avoided by shutdown of the unit within 4 hours.

Immediate Shutdown - There is clear evidence of rapid boiler tube damage by low
boiler water pH. Immediate shutdown of the unit is required to avoid such damage.

Rationale for Target Values of Individual Parameters

 Parameters Explaination
Corrosion of metals is a function of pH
Alkaline pH values increase the
stability of magnetite film and reduce
magnetite solubility in water
Corrosion rate of carbon steel reaches
minimal values over the pH range of
pH
9.2 9.6
Immediate shutdown is recommended
for low drum boiler water pH < 8
could lead to severe localized attack
on waterwall tubes

Monitoring of ammonia can be used to

supplement the direct measurement of
pH and/or specific conductivity for the
control of the ammonia feed rate
Ammonia The ammonia concentration should be
consistent with the pH requirements

An inexpensive, reliable, online

method for monitoring the overall level
of concentration, treatment chemicals
and their trends
Specific conductivity at the
economizer inlet is an indication of the
Specific conductivity ammonia level and hence pH, during
normal operation, since other ionic
impurities are relatively low
The specific conductivity target value
should be consistent with ammonia
level

Serves as an excellent diagnostic

 tools as the cations are removed via
cation exchange and the H+ has the
markedly higher equivalent
conductance than all other cations
Cation conductivity Continuous measurement in steam
provides a reliable indication of the
presence of harmful salts and acids
that are known to cause turbine
corrosion

Precipitation of silica forms silicate

deposits on the turbine that are not
soluble in water and very difficult to
Silica remove
Silicate deposits cause losses in
turbine capacity and efficiency

Corrosion fatigue, stress corrosion

cracking and pitting in LP turbines
Corrosion, hydrogen damage and
Chloride
pitting in boiler

Chloride limit of 2 ppb in steam is

necessary to avoid damage to boiler &
turbine, and help to minimize
deposition in the LP turbine

Monitoring of sodium is required

because sodium compounds such as
NaOH & NaCl are two major
corrodents of turbine and SS
Sodium superheater tubes
High NaOH concentration have in the
past caused gouging-type failure of
boiler tubes.
Oxygen reacts synergistically with
chloride, resulting in hydrogen
damage boiler tube failure
Dissolved Oxygen Monitoring of DO at the deaerator
 outlet serves as a check for the
effectiveness of deaeration

2.1.1.3 Method use in water chemical analysis

In third week of my practical training, my lab technicians told me about the purpose
of the lab in this plant. The purpose was to monitor the parameters of water that
comes from different part of the plant. Water plays an important role in this plant
because water contains physical and chemical properties which it can changes at
different condition if its surrounding was altered. So, the lab technicians were been
responsible to monitor and did several analysis from different location of water from
plant to make sure the parameter of water follow their standard. Usually, water in this
plant was been measured by several units. Ppm and ppb unit was used in water
analysis to determine its parameter concentration such as chloride and silica.

In laboratory, there were certain instruments and machines that been used by the
technicians to did an analysis. For instance, spectrophotometer, pH meter,
conductivity meter, dissolved oxygen meter, and uv-mini spectrophotometer. Each of
these instruments analyse different type of parameters. So, the lab technicians teach
me each of the instrument functions and their procedure while conducting an
analysis. Ph, dissolved oxygen and conductivity meter have a same technical
 concept about their analysis method. It just simply put the analyser meter in the water
sample and make sure it completely immersed finally waited until the reading was
stable and take the reading.

Furthermore, another instrument such as spectrophotometer and uv-mini

spectrophotometer also have same concept that was absorbance. Absorbance can
be calculated by shooting a stable light beam pass through the sample from one end
to another. If the sample has dark in colour or had many interferences in it, thus its
absorbance was high, hence it produce less light compare to light that was originally
shoot. This complex process of absorbance was been done automatically by
spectrophotometer and uv-mini. We just take care of how the analysis procedure was
and when finished, just put it into the instrument and push read button and result was
recorded.

Last but not least, I also used titration method to analyse certain parameter such as,
total hardness and hydrazine test. In titration method, neutralization process was
occurred during this analysis. It because, basic and acidic solution was mixed
together until end point was reached. End point was indication for titrant completely
neutralize by basic solution.

2.1.1.4 Analysis of water steam cycle chemistry

Water steam cycle consist of several type of water that must been monitored by lab
technicians twice a week. This analysis actually was held in Monday and Thursday.
The types of water included in water steam cycle chemistry were:

Makeup water
Condenser extraction pump
Deaerator
Economizer
Boiler drum
Mainsteam

I was done analyse each of the waters parameter by using certain method and
different type of instruments. Below were example that I did some analysis that Ive
done every Monday and Thursday.

Determination of Total Organic Carbon (TOC) in makeup water sample by using

spectrophotometer
 1) 0.4ml of makeup water was been measured by electrical pipette and put it
into the beaker.
2) Beaker was put into the stirrer and stirred about 5 minutes
3) Meanwhile, put the TOC powder pillow reagent in an empty test tube.
4) After 5 minutes done, the beaker was pour into the test tube and shaked well.
5) The blue indicator was put into the test tube.
6) Test tube was put into the heater and been heat at 1050C for about 2 hours.
7) After 2 hours, test tube was been cooled about 30minutes and put into the
spectrophotometer.
8) Result was recorded.

Determination of Dissolved Oxygen (DO) in condenser extraction pump (CEP) and

deaerator by using DO meter.

1) About 100ml of CEP water was put into the beaker.

2) The sensor in DO meter was immersed fully in the beaker and wait about 1
minute until the reading become stable.
3) The result was recorded.
4) Step 1-3 was repeated by using deaerator water

Determination of pH meter in deaerator, economizer and boiler drum water by using

pH meter.

1) About 100ml of deaerator water was put into the beaker.

2) The sensor in pH meter was immersed fully in the beaker and wait about 1
minute until the reading become stable.
3) The result was recorded.
4) Step 1-3 was repeated by using economizer and boiler drum water.
 Determination of specific conductivity in economizer and boiler drum by using
conductivity meter

1) About 100ml of economizer water was put into the beaker.

2) The sensor in conductivity meter was immersed fully in the beaker and wait
about 1 minute until the reading become stable.
3) The result was recorded.
4) Step 1-3 was repeated by using boiler drum water.

Determination of phosphate in boiler drum water by using spectrophotometer

1) 10ml of deionized water (DI) was pour into cuvette bottle and labelled as
blank.
 2) 10ml of boiler drum water was pour into cuvette bottle.
3) Blank was put into the spectrophotometer to take zero reading.
4) A powder pillow of phosphate reagent was added into boiler drum water
sample cuvette bottle.
5) 3minutes had been timed before reading taken by using spectrophotometer
timer to make the reagent homogenize with water sample.
6) Blank was put out and boiler drum water sample was put into
spectrophotometer and reading was recorded.

Determination of Chloride in boiler drum and mainsteam water by using uv-mini

spectrophotometer.

1) 50ml of DI water and 50ml of boiler drum was pour into conical flask
separately and DI water flask was labelled as blank.
2) Both of the flask was been added 5ml of HNO3 by using pipette.
3) Timer was set for 5 minutes to make sure the the solution become
homogenize
4) After 5 minutes, 1ml of AgNO3 was been added both of the flask bu using
electrical pipette.
5) Blank solution was put into cuvette and put into the uv-mini
spectrophotometer to take zero reading.
6) Boiler drum was put into cuvette and put into the uv-mini spectrophotometer
and absorbance reading was recorded.
7) Step 1-6 was repeated by using mainsteam water.
Determination of silica in boiler drum and mainsteam water by using
spectrophotometer.

1) 50ml of DI water was pour into conical flask and labelled as blank.
2) 1ml of molybdate and 1ml of citric acid was added in blank.
3) Repeat step 1-2 by using boiler drum water
4) Timer was been set to 4minutes by spectrophotometer for waited the solution
to homogenize.
5) 1ml of amino acid was added to boiler drum water only.
6) Another timer was been set about 1 minute by spectrophotometers timer.
7) Blank was poured first into the spectrophotometer to get zero reading.
8) Boiler drum was poured into the spectrophotometer and result was recorded.
9) Step 1-8 was repeated by using mainsteam water.
2.1.1.5 Analysis of water from different location of the plants.

Besides water steam cycle chemistry monitoring, we also analyse different type of
waters from certain locations to monitor it weekly. Sometimes the water sample had
to be analyze if its locations had operated it. Example was water from Water
Treatment Plant (WTP). We only analyse this type of water if WTP was running.
There were certain parameter that should be monitored when in an analysis.
Different type of water has different type of parameters that we should be monitored
on. This week I did an analysis of water from raw water, ash pond, cooling water
outlet, WTP, and Waste Water Treatment Plant (WWTP). I did this analysis on
Monday, Wednesday and Friday. Below was analysis that Ive been done in this
week.

Determination of total hardness in raw water sample by using titration method

1) 50ml of raw water boundary and DI water was pour into conical flask.
2) 4ml of buffer was been measured by pipette and added into the flask.
3) 6 drops of Black-t was been added to act as an indicator and the solution
became purple in colour.
4) 5ml of EDTA was pour into 5ml of burette and flask was place as a titrant.
5) The flask was put on a white tile to make it easier to detect its end point
6) Slowly dropped EDTA solution into titrant and stoped until end point was
reached.
7) Observation and result were recorded
8) Step 2-7 was repeated by using raw water tank.

Discussion : Observation of the solution after been added by black-t indicator was
purple in colour. Neutralisation process was involved in this analysis. It because
EDTA was a basic solution while the titrant which contain buffer was in acidic
solution. In this experiment, we want to know how much EDTAs solution can
neutralize the titrant thus, this titrant volume will undergoes some calculation to
calculate the amount of total hardness.

Total hardness, (ppm) = Titrant volume x EDTAs factor (1.09) x 1000

Sample volume
Determination of iron in ash pond water by using spectrophotometer

1) 10ml of DI water was pour into cuvette and labelled as blank.

2) Blank was put into the spectrophotometer to take zero reading.
3) 10ml of ash pond water was pour into cuvette bottle.
4) A powder pillow of iron reagent was added into boiler drum water sample
cuvette bottle.
5) 3minutes had been timed before reading taken by using spectrophotometer
timer to make the reagent homogenize with water sample.
6) Blank was put out and boiler drum water sample was put into
spectrophotometer and reading was recorded.

Determination of free chlorine in Water Treatment Plant (WTP)

1) 10ml of DI water was pour into cuvette and labelled as blank.

2) Blank was put into the spectrophotometer to take zero reading.
3) 10ml of activated carbon filter inlet water was pour into cuvette bottle.
4) A powder pillow of free chlorine reagent was added into activated carbon
filter inlet water sample cuvette bottle.
5) 3minutes had been timed before reading taken by using spectrophotometer
timer to make the reagent homogenize with water sample.
6) Blank was put out and water sample was put into spectrophotometer and
reading was recorded.
7) Step 1-6 was repeated by using activated carbon filter outlet.
 Determination of Boron in Cooling Water Outlet (CWO) by using spectrophotometer

1) 75ml of H2SO4 and boron powder pillow was been added into conical flask
and labelled as solvent.
2) 2ml of DI water was pour into new conical flask and been added 35ml of
solvent and labelled as blank.
3) 2ml of CWO was pour into new conical flask and been added 35ml of solvent
and labelled as sample.
4) Transfer the blank and sample into cuvette bottle and timed it 25 minutes to
make sure the solution was homogenize.
5) Blank was put first into spectrophotometer to take zero reading.
6) Sample was put after the blank and reading was recorded.

Determination of pH in WWTP by using pH meter.

1) About 100ml of monitoring tank water was put into the beaker.
2) The sensor in pH meter was immersed fully in the beaker and wait about 1
minute until the reading become stable.
3) The result was recorded.

2.1.1.6 Tour trip to plant sites

In this week, in guidance with my technicians, I was been given a personal tour trip
to all locations of the plant. Examples of locations that Ive visited were :

Boiler house
1. Definition: A closed vessel that safely, reliably and efficiently transfer
heat released during combustion of fuel in which water and steam
were heated under pressure.
2. Purpose: To convert demineralized water by heating at very high
temperature by using pulverised coal as main fuel into steam and
pass it through turbine.
3. It has very high temperature and pressure in it. Condition in boiler
according to thermodynamic study was in sub-critical condition.
4. Boiler functions :
To release energy in fuel as efficiently as possible.
To transfer the released energy to the water and to generate
steam as efficiently as possible.
To separate steam from water where the energy can be
transferred to the process as efficiently as possible.
5. Boiler condition must be slightly alkali because if it was too acidic, it
will cause corrosion in piping tube and the efficiency of boiler will
reduce.

Boiler House Inside boiler house

Electrochlorination Plant
1. Purpose : Inject sodium hypochlorite (NaOCl) to sea water before sea
water pass through the condenser as a cooling medium.
 Chemical top-up in Electrochlorination plant

Workers were wearing overall for those who in duty for top-up because we were
handling quite concentrated chemical that was 40 M NaoH

Electrostatic Precipitator (ESP)

1. Purpose : Trap fly ash in flue gas system and sold it to Lafarge
company for cement industry.
 Coal bunkers
1. Purpose : Receive coal from last junction tower and sent to coal
feeder for mixing ratio for coal.

Coal Bunkers

2.1.1.7 Coal and fly ash analysis

Coal Analysis

Generally, in this plant, we used coal as our main fuel instead of fuel. We choose
coal because :

Abundant Reserve compared to oil and Gas i.e. last longer

Cheaper than Oil
Stable market price
 In laboratory, my lab technicians and I were supposed to monitor its physical and
chemical properties of coal that been used as a fuel to our plant. There were 2 types
of coal used it were bituminous and sub bituminous thus, it was grade as A and B+
respectively.

This week I was been told by supervisor to learn and did some analysis about coal
and fly ash. From what that Ive learned, it had 3 types of coal analysis. It were :

Proximate analysis
Total moisture, residual moisture, ash content, volatile matter, and
fixed carbon
Ultimate analysis
C, H, N, Total sulphur
Gross Calorimetric Value (GCV) analysis

Coal analysis flow chart process

Coal sample
from ship
arrived in lab

Undergoes free
moisture content
analysis
 Coal was grind at size
about 0.15 mm for
further analysis

Undergoes proximate,
ultimate and gross
calorimetric value analysis

Proximate analysis

Proximate analysis has 2 different type of analysis :

Total moisture content

Fixed carbon

1. Total Moisture Content Analysis

In order to calculate total moisture content, I have to know its free moisture content
and residual moisture content first. It because these 2 types of moisture will be
included in calculation of total moisture content. Below were the procedure of how did
I did analysis for free moisture and residual moisture content.

As we know, in analysis for free moisture content, we need an original coal that came
from ship. So, grinding the coal was not the best option to maintain its original
chemical properties. I was used raw sample coal that originally came from ship.

Determination of free moisture content in coal from ship by using oven method

1. 650g of small and smooth coal were picked and weighed from sample
bag rather than big and hard coal for better analysis by using weighing
balance.
2. Sample was put in a tray and been weighed.
3. Weight of tray with sample was recorded before heating in the oven.
4. Sample was placed in the oven at 40oC overnight.
5. Weight of tray and sample after heating was been recorded by using
weighing balance.
6. Difference between mass of sample and crucible before and after
heating was calculated.

Residual moisture content analysis was up next, but I must grinded the for getting a
better and precise result. Certain coal analysis must be grinded first before putting it
into its instrument because certain instrument in lab cannot read a bigger and hard
coal sample. So, grinded it first would be necessary for that problem. Grinded coal
size must be about at 0.15mm for better analysis.

Determination of residual moisture content by using oven method

1. About 1g of sample was weighed by using weighing balance and put into a
crucible.
2. Step 1 was repeated because to make an average reading.
3. Crucible and sample was been weighed before heating in the oven.
4. Sample was placed into the oven at 107oC for 1 hour.
5. Crucible and sample after heating was been weighed by weighing balance.
6. Difference between mass of sample and crucible before and after heating
was calculated.

After 2 analysis of free moisture and residual moisture content been done, now I can
calculate its total moisture of content of this type of coal.
 2. Fixed Carbon Analysis

In fixed carbon analysis, we have 2 types of analysis that we must undergoes first to
calculate the fixed carbon. That were:
Volatile matter content
Ash content

Determination of volatile matter content by using oven method

1. Before analysis was done, the useable crucible must be preheated in the
oven at 9500C for 2minutes to eliminate the residual coal in the crucible.
2. After crucible was cooled down, sample was weighed about 1g and put
into crucible by using weighing balance.
3. Mass of crucible and sample before heating were weighed and recorded.
4. Step 2-3 was repeated for average reading.
5. Sample was put into the oven at 9500C for 7 minutes.
6. Crucible was let cooled and been weighed.
7. Mass of crucible and sample was weighed by weighing balance and
recorded.
8. Difference between mass of sample and crucible before and after heating
was calculated.

Determination of ash content by using oven method

1. Sample was been weighed about 1g by using weighing balance and put into
the crucible.
2. Mass of crucible and sample before heating was recorded.
3. Sample was placed in the oven and been heated from 0-5000C for 1 hour and
30 minutes.
4. Temperature was increased from 500-8150C for another 1 hour.
5. Crucible was placed in the dessicator to let it cooled
6. Mass of crucible and sample after heating was weighed and recorded.
7. Difference between mass of sample and crucible before and after heating
was calculated.

Both analysis had been done, so the fixed carbon now can be calculated. Hence, the
proximate analysis had been finalize.

Ultimate analysis

Ultimate analysis contains several analysis. Such as:

1. C,H, and N analysis

 2. Total sulphur analysis

Determination of C,H, and N in coal by using oven method.

1. Mass of sample was weighed about 0.15g by using weighing balance and
was placed in aluminium foil and been recorded.
2. This foil then was been tied up before put it into the oven
3. Temperature was been set in computer at 9500C for initial temperature while
8500C was set for final temperature.
4. Sample was put into the machine for 5 minutes and the quantitative result (%)
for C, H and N was pop up in computer screen.
5. Result (%) was recorded.

Determination of total sulphur in coal by using oven method

1. Sample was been weighed about 1g and placed it in crucible by using

weighing balance.
2. Temperature was been set in computer at 1350 0C and crucible was placed in
the oven.
3. After 5 minutes, total sulphur of coal was popup in window screen and results
was recorded.

Gross Calorimetric value (GCV) Analysis

This purpose of the analysis was to measure the calorific value of coal in this plant.
Generally, the higher the calorific value, the better the coal was. In this analysis, I use
a bomb calorimeter and fused wire to determine the calorific value. The concept was,
the fused wire that must be applied an electric on it was placed above the surface of
the coal. While, this fuse wire and coal was placed in the bomb calorimeter. After
that, bomb calorimeter was placed in the GCV machine.

Determination of gross calorimetric value by using GCV machine.

1. Coal was been weighed about 1g and placed in crucible.

2. Crucible was put into the bomb calorimeter which contains a fused wire that
placed at above the surface of coal.
3. Bomb calorimeter was put into GCV machine to fused the wired with
electricity.
4. After 5 minutes, bomb calorimeter was put out and opened to measured how
much the fused wire was burnt in presence of coal.
5. Fused wire was been measured by using a ruler and the fused wired length
value was entered into the GCV machine.
6. GCV machine will automatically give a result and result was recorded.
Fly ash analysis

As we know, fly ash was produce in this plant by trapping the flue gas by using electrostatic
precipitator (ESP).

Loss on Ignition (LOI) analysis

Objective : To measure boiler combustion efficiency

Limit : < 5%

Fly ash sample : RAPH, ESP, Silo

Daily Monitoring (Morning & Afternoon)

Fly ash sold to Lafarge for cement production.

Determination of Loss on Ignition of fly ash by using oven method

1. Sample was taken manually at ESP and been weighed about 1g by using
weighing balance and put it into the crucible.
2. Mass of crucible and sample before heating was recorded.
3. Crucible was put into the oven at 9500C for 25 minutes.
4. Crucible was let it cooled and mass of crucible and sample after heating was
recorded.
5. Difference between mass of sample and crucible before and after heating
was calculated.
2.1.1.8 Determination of sulphur content in all type of coal that been used by plant.

This week my supervisor told me to do an analysis about sulphur in coal. So, he ask me to
did an analysis about which of the coal have highest and lowest amount of sulphur. Below
was the result that I did the analysis.

Coal Types Weight (g) Sulphur (%) Sulphur (mg)

Carbo One 0.3509 0.43685 1.5329

0.3503 0.47857 1.6764

BHP 0.3503 0.80084 2.8053

0.3504 0.81007 2.8385

MSJ 0.3500 1.5138 5.2982

0.3507 1.5218 5.3370

Kayan 0.3508 0.33473 1.1742

0.3501 0.32233 1.1285

Rio Tinto 0.3502 0.75915 2.6585

0.3506 0.78671 2.7582

Peabody 0.3501 0.69512 2.4336

0.3505 0.69607 2.4208

MT Owen 0.3504 1.0476 3.6676

0.3501 1.0355 3.6283

RSA 0.3509 0.64127 2.2502

0.3501 0.60296 2.1110

Ensham 0.3503 0.90022 3.1535

 0.3504 0.95744 3.3549

Prime Coal 0.3509 1.1327 3.9746

0.3504 1.1341 3.9740
Based in the result, it shows that, MSJ coal type has the highest amount of sulphur while
Kayan coal type has the lowest amount of sulphur. In coal terminology, for coal which
contains less sulphur was better brand coal rather than high sulphur contains. Based on this
analysis, it showed that Kayan was better coal typed rather than MSJ because it contains
less sulphur.

There 2 types of coal that been used in this plant. It were bituminous and sub-bituminous.
These coal typed contains certain chemical properties that we can identified from it. Below
was the table about its chemical properties about the coal.

Parameters Bituminous Sub-Bituminous

GCV (kcal/kg min) 5900 5000

Total Moisture (% max) 18 26

Ash (% max) 15 5

Total Sulfur (% max) 1 1

HGI (min) 37 40
2.1.1.9 Environmental Monitoring

This week, I followed one of my technician whose under environment part to did an
environmental monitoring in Tanjung Bin power Plant (TJPP). Malakoff was hired
another 3rd party contractor to did certain analysis for environmental monitoring.
Then, this environmental report will send to Department of Environment (DOE) and
DOE itself will examine and take actions of the report. Malakoff hired another party to
distributed in this monitoring for TJPP instead of Malakoff itself because we wanted
to avoid biased condition in this project. So, the third party contractor that been doing
the monitoring was Chemlab.

In environment monitoring, there were certain types of area that been monitored such
as:

Chimney Emissions
Cooling water outlet (CWO) discharged
Marine water
River water
Storm water
Ground water

For environment monitoring at marine and river water, we were riding a boat to get a
sample and did on the spot analysis. There were 2 types of analysis that been done
by the 3rd party such as:

In-situ analysis
Laboratory Analysis

In situ analysis contain several parameters that must be monitored. This parameters
must be analyse directly from the locations. The parameters that been monitored
were:

Chlorine
Dissolved Oxygen (DO)
pH
Temperature

Marine water In-situ Analysis

In marine water analysis, we were taking a sea water as a sample and been analyse its
parameter on the spot.

Groundwater In-situ analysis

In ground water analysis, we were taking ground water near the ash pond to monitor is there
any leakages of ash pond water ingress in ground water.

Monitoring at groundwater 1 Monitoring at groundwater 2

 View at ash pond water In-situ analysis for pH and boron test

In-situ analysis for storm water.

In storm water, we were taking a rain water pond as a water sample and been analysed on
the spotted.

Storm water sample taken in the afternoon In-situ analysis for chlorine test
Monitoring chimney emission

There were certains parameters that must be achieved. If heavy metal was detected,
the 3rd party contractor will analyse its concentration whether it was could harmful to
us or not. It will be safe if the heavy metal was in low concentration. Example of the
parameters were:

SO2, CO, NOx < 500mg/Nm3

Particulate Matters < 50mg/Nm3
Heavy metals : Arsenic, Lead must be in low concentration.

Environment monitoring with my technician At the top of chimney

Flue gas desulphurization final checkpoint Final floor at chimney

2.1.1.10 Study the process of electro chlorination plant (ECP)

ECP was needed in this plant to remove unnecessary microorganism and organic material
that comes from sea water. Sea water was used as a main cooling water (MCW) system in
this plant. Meaning, sea water was act as coolant in condenser to convert steam to water
and used it back in the boiler and cycle was completed.

Function & purpose:

To produce sodium hypochlorite from seawater.

Sodium hypochlorite is used to prevent bio-fouling in MCW System.

Sodium hypochlorite (NaOCl) was used to inject it in sea water intake to remove the organic
materials. Actually, we produced the NaOCl was from sea water itself. NaoCl produced from
sea water by using electrolysis process. Acid cleaning system was introduced to ECP to
clean the anode and cathode for better eeficiency of electrolysis process. These were the
example of the flow process.

Sea water was been

applied an electrolysis
reaction

NaOCl was produced

from the reactions

NaoCl was injected in

sea water

Sea water was been

fit to act as MCW
system
2.1.1.11 Study the process involved in water treatment plant (WTP)

WTP was needed in plant because it convert raw water (raw water from Syarikat Air Johor)
to demineralised water for boiler used. Demineralization process was been applied in this
system. There were some principles in demineralization process such as:

Demineralization - removal of all inorganic salts from solution by ion exchange. In

this process, cation exchange converts dissolve salts to acids, and anion exchange
removes these acids and leaving pure water.

The demineralization system consists of two or more ion exchange vessels including
a cation exchanger unit and an anion exchanger unit

Ion exchange is the reversible exchange of ions between solid and liquid in which
there is no substantial change in the structure of the solids.

Function and purpose of WTP:

To produce 2640 m3/day demineralized water for boiler use.

Treated water quality:

a) Silica as SiO2 < 20 ppb

b) Conductivity < 0.5 S/cm

 Water Treatment Plant (WTP) overall process.
Raw H20,

pH 6-8 2 Bed 3 Towers

Activated Carbon Filter,

Cation Exchanger, CE Degassifier Anion Exchanger, AE Bed Exchanger,
Mixed
ACF MBE

Remove Replace Remove Replace

Cl, cation (i.e CO2 using anions (i.e
organics,
Ca2+,K+, air blower Cl-,SO42-, Demin H20,
SS Exhibits
regen : Na+, Mg+) CO32- with
Counter flow
pH 6-8
demin with H+ process -
water OH )
pH where water Regen: Silica < 20 ppb
was comes NaOH 1%
2.0-3.0 from above & 3% Sp Cdty <0.5 s/cm
while air was
regen: HCl blown from
4% below
2.1.1.11 Study the process of Waste Water Treatment plant (WWTP)

Purpose of WWTP was built in this plant was :

To treat process effluents or waste water from various points in the power plant and
discharging to seawater basin.

There were 3 types of waste in plant such as:

a) Regular Waste
- Boiler blowdown
- WTP waste
- sampling system
b) Irregular Waste
- Start up
- Laboratory
- RAPH washing
- Boiler acid cleaning & hydro test
- Cooling water cleaning
c) Oily Waste

- Turbine building
- Transformer yard
- Oil yard tank
 Waste Water Treatment Plant (WWTP) overall process overview

1) Pre-retention basin
To store irregular waste from intermittent events such as boiler chemical
cleaning
These wastes tend to be highly concentrated. It will be diluted into Retention
Basin using Irregular waste water pump.

Pre-retention basin
2) Oil separator
When wastewater laden with oil passes though the plates, oil which is less
dense, is collected at the top and water overflow via a nozzle located at the
bottom
Oil is collected at the Oil Collection Tank for disposal
Treated effluent then flows into the Retention Basin for further treatment

Oil separator tank

3) Retention Basin
Collection point for all waste water before further treatment
Sources :
Waste from CPI separator units
Concentrate waste from Pre Retention Basin
Boiler blowdown, sampling system, WTP

Retention basin

4) Reaction tank
 Reaction Tank is where the wastewater coagulated and prepared to solids
settling
pH is control at 9 to 10 by Acid & Alkali Dosing System
FeCl3 is dosed to facilitate the coagulation process using FeCl3 Pump
Suspended solids are lumped together in larger flocs as FeCl3 provides ionic
charge to the suspended solids particles and as results the particles stick
together due to inter-charge attraction potential hence leading to coagulation.
5) Coagulation tank
Polymer is dosed into Coagulation Tank to increase the flocculation potential
of particle after coagulant is dosed
This is important when suspended solids concentration is low and there is
difficulty in forming larger flocs and settling

Coagulation and flocculation concept

6) Clarifier
The suspended solid have high settling velocity due to its weight and size will
settle at the bottom of clarifier basin, leaving a clear layer of supernatant at
the surface of effluent
A scrapper is located at the bottom of the tank will sweep the settled sludge
into the bottom of clarifier where it will be transfer to the Thickener by Sludge
Pump
The treated supernatant will overflow over a weir plate and be directed into
Neutralization Tank
 Clarifier overview process

7) Thickener
The thickener serves to thicken the sludge to reduce the sludge volume
needed to be disposed
Sludge is then transferred to Sludge Tank by using Sludge Pump
The supernatant flows over the weir plate and collected together with clarifier
supernatant to be transferred into Neutralization Tank for final treatment

Thickener overview process

8) Filter Press
From the Sludge Tank, sludge will be transferred to the Filter Press by air
diaphragm pump
The function of Filter Press is to compress the sludge to produce sludge cake
that is low in moisture content
The water pass through the filter cloth and directed back to Retention Basin,
while solids retain in the chambers
Upon completion of the filtration process, the filter plates are opened and the
sludge cake drops onto the sludge hopper
 Filter press system was designed to remove moisture in sludge

9) Neutralization Tank
In Neutralization Tank, HCl is injected to adjust the pH of treated water to 5.5 -
9.0, as per DOE Standard B requirement
A pH sensor is located in this tank to control the amount of required chemical
dosage and a mixer is installed for sufficient mixing of solution
After pH adjustment, the treated water will flows over a weir to Treated Water
Tank before being transferred to Monitoring Tank.

Neutralization tank in Waste Water Treatment Plant (WWTP)

10) Monitoring Tank

Monitoring Tank is use to monitor the final treated waste water effluent before
final discharge
pH monitoring and recording is done here and alarm will trigger when pH
value is out of the specification limit
 The discharge water quality shall comply to DOE Environment Quality Act
(Sewage and Industrial Treatment) Regulation, 1979: Standard B

Monitoring tank rear view

Monitoring tank in closer look

2.2 Working experiences

There were many experiences that I gained when I did the intership programme
in Tanjung Bin Power Plant. While I carried out my project such as doing some
analysis in lab, I gain some experienced about team work where the lab technicians
and I were doing analysis together. Meanwhile, they also very punctual in time when
 conducting their task such as refilling ammonia chemical in chemical dosing three
times a week. Usually, we were refilling in Monday, Wednesday and Friday. In
laboratory, there were certains apparatus that quite handy compare to my institution
such as electrical pipette, and marked dropper. Electrical pipette was very useful
because it contains 2 buttons, sucked and blow button. By controlling these buttons
we can get reading in pipette in shortest time.

I also had assisted my supervisory work such as arranging documentations and

files. While working with him, we had finished our works in shortest of time
eventhough it had many documents and files that need to be cover. It because, my
supervisor hates procrastination and he wants this task was finished as fast as it
could. By observing my supervisors action, I can tell that someones effectiveness of
work depends on their effort and enthusiasm .So, I take this as my motivation to did
my work and task more efficient.

While I practical in here, there were certains problems that arise. For example,
the workers in Tanjung Bin Power Plant, had low self-awareness. They were not
taking care of themselves while dressing Personal Protective equipment (PPE).
Example of their mistake was not wearing the safety helmet correctly where they not
applied a shin guard at it. Shin guard must be applied because safety helmet will fell
down if our head headed down while doing construction works. Furthermore, they
also were not wearing a face mask and ear guard properly. If they just take these
things for small matter, their life maybe on it stake. So, in order to solved this
problem, Safety department was been told to monitor all the workers in plant each
hour to make sure the workers were wearing a proper PPE attire. If they didnt follow
any of attire regulations they will take a serious action and maybe given a penalty.

In my experiences, safety in work must be take serious action in individually to

prevent any minor and major accident or even near miss while conducting such risky
work in plant.

CONCLUSION AND RECOMMMENDATIONS

In my view after been practical here, the workers in this plant even in lab, they should
wear a Personal Protective Equipment (PPE) more properly when in site or even conducting
an analysis. I recommend that, during morning briefing with section head in admin building,
we should view some safety video every morning to increase our awareness towards
hazards in our surrounding by properly wearing a PPE.
The opportunity to work with Tanjung Bin Power Plant (TBPP) provided the chance to
experience a variety of laboratory works. A bunch of thanks to Tanjung Bin Power Plant for
allowing me to undertake my industrial training with them, share knowledge and experiences
that they have.
The water and coal tests that I have done has allowed me to learn a lot on water and
coal quality that needed by the plant in order to have an efficient flow of the process. Apart
from that it taught me on how to do a proper experiment on every analysis that have been
done so far. It is a common type of task or work that opens the doors for progress into the
next level, which in turn is an area where many of my skills will be greatly utilized.
The most significant part of my two and a half months of industrial training is that I
was able to experience a variety of works and jobs that I may apply in my future career. I
also was able to observe the work culture in the laboratory and plant that I was placed in
during the period.
Apart from that, TBPP also gave me a good picture of working life as the staffs are
just like one family and I learnt how to overcome a problem that arises by discussing and
sharing ideas with one and another. I hope that I can get this kind of working environment
once I get into that level.

References

1. Malakoff background. Retrieved February 3, 2015, from

http://www.malakoff.com.my/About-Us/Board-of-Directors/
2. What is Flow-Accelerated Corrosion. Retrieved February 3, 2015, from
http://www.corrosionpedia.com/definition/1342/flow-accelerated-corrosion-fac
3. Malakoff corporate background. Retrived February 3, 2015, from
http://www.malakoff.com.my/About-Us/Corporate-Background/
4. Water Chemistry slide (TBPP INTEGRATED LEARNING SOLUTION)
5. Boiler Chemistry slide (TBPP INTEGRATED LEARNING SOLUTION)
6. TBPPs library
7. Chemical Services staffs
8. MSDS of Sodium Triphosphate. Retrieved February 3, 2015, from
http://www.cleartech.ca/msds/trisodphos.pdf
9. MSDS of Ammonia. Retrieved February 3, 2015, from
http://avogadro.chem.iastate.edu/MSDS/NH3_gas.pdf
10. MSDS of Hydrazine. Retrieved February 3, 2015, from
http://www.sciencelab.com/msds.php?msdsId=9924279
11. MSDS of Sodium Hydroxide. Retrieved February 3, 2015, from
http://www.certified-lye.com/MSDS-lye.pdf
12. MSDS of Sulphuric Acid. Retrieved February 3, 2015, from
http://www.exide.com.au/industrial/specs/sulphuricacid.pdf