THE INSTITUTION OF ENGINEERS
SRI LANKA
REPORT ON TRAINING AND EXPERIENCE
FOR
PROFESSIONAL REVIEW
August/September 2016
Eng. A.P.Sampath
B.Sc. Eng. (Hons), MEng. , AMIE (SL), AM (SLEMA)
Mechanical Engineer
Ceylon Electricity Board
IESL MEMBERSHIP NUMBER AM-10327
15.07.2016
1
DECLARATION
I hereby declare that the details on Training and Experience presented in this Report are on my
own work based on past training and experience.
…………………
Eng. A. P. Sampath
B.Sc. Eng. (Hons), MEng, AMIE (SL), AM (SLEMA)
15.07.2016
2
ACKNOWLEDGEMENTS
University of Ruhuna and University of Moratuwa are the places where I grew up in Mechanical
Engineering. Therefore, my sincere gratitude goes to them for paving my way for the prestigious
profession of Mechanical Engineering. It is the knowledge I could gathered through the
academic process that gave me this career opportunity.
My very first training experience was at the Sri Lanka Transport Board. It was a valuable
opportunity to start my career as a trainee Mechanical Engineer. My second and final training
experiences were taken from Lanka Walltile PLC and National Engineering Research and
Development Centre respectively. There I was able to build up confidence on theories with
respective to their practical applications. Therefore, I express my deep appreciation to the
superiors of the organizations those who helped me to make my career a success.
My very first experience as a graduate engineer was at the International Precision
Moulds & Tools (Pvt) Ltd as an operation trainee Engineer. It was a valuable opportunity to
start my career as a Mechanical Engineer. There I was able to build up confidence to hold
responsible positions in any organization. Next was as an Assistant Engineer at Trinity Packaging
(Pvt) Ltd Under servicing to Unilever. The valuable experience I have gained by working with
the managers and the engineers of the company has immensely contributed to the much needed
confidence for the responsibilities of career. Therefore, I am grateful to the superiors of the
organization who helped me to make my career a success. Ceylon Electricity Board (CEB) being
the largest power utility in Sri Lanka and it is the place where I gained a vast experience in the
field of Mechanical Engineering. I am extremely thankful to my superiors of the CEB for their
guidance and encouragement, which has helped to make my career a success as a Mechanical
Engineer.
Eng. A. P. Sampath
B.Sc.Eng. (Hons.), MEng., AMIE (SL), AM (SLEMA)
apradeeps@gmail.com
15.07.2016
3
TABLE OF CONTENTS
DECLARATION ........................................................................................................................ 2
ACKNOWLEDGEMENTS ....................................................................................................... 3
TABLE OF CONTENTS ........................................................................................................... 4
LIST OF FIGURES .................................................................................................................... 6
LIST OF ABBREVIATIONS ..................................................................................................... 7
CHAPTER 01.............................................................................................................................. 8
1.1 INTRODUCTION ............................................................................................................ 8
CHAPTER 02............................................................................................................................ 10
2.1 SUMMARY OF RECOGNIZED TRAINING AND RESPONSIBLE EXPERIENCE 10
2.1.1 Recognized Training Prior to Graduation (Vide Rule 5.8.1.2) Total: 9 Months .. 10
2.1.2 Recognized Training after Graduation (Vide Rule 5.2.2) Total: 3 Months .......... 10
2.1.3 Responsible Experience (Vide Rule 5.3)Total: 87 Months .................................. 11
2.1.4 Exemptions (Rule 5.5) .......................................................................................... 11
2.1.5 Break Down of Total Training and Experience .................................................... 12
CHAPTER 03............................................................................................................................ 13
3.1 RECOGNIZED TRAINING PRIOR TO GRADUATION ............................................ 13
3.1.1 In-Plant Training at Ruhunu Bus Company Limited ............................................... 13
3.1.2 In-Plant Training at National Engineering Research & Development Centre
(NERDC). ......................................................................................................................... 13
3.1.3 In-Plant Training at Lanka Wall Tile Meepe (Pvt) Ltd – Meepe, Sri Lanka. .......... 15
....................................................................................................................................... 16
CHAPTER 04............................................................................................................................ 17
4.1 RECOGNIZED TRAINING AFTER GRADUATION ................................................. 17
4.1.1 International Precision Moulds and Tools (Pvt) Limited ........................................ 17
CHAPTER 05............................................................................................................................ 18
5.1 RESPONSIBLE EXPERIENCE ..................................................................................... 18
5.1.1 Department of Mechanical & Manufacturing Engineering, Faculty of
Engineering,University of Ruhuna ................................................................................... 18
5.1.2 Trinity Packaging (Pvt) Ltd ..................................................................................... 18
5.1.3 Ceylon Electricity Board.......................................................................................... 18
5.1.3.1 Generation Division of CEB ............................................................................. 19
5.1.3.2 Mechanical Engineer, Fuel System at Kelanitissa Power Station of CEB ....... 19
5.1.3.3 Mechanical Engineer, Gas turbine at Kelanitissa Power Station of CEB......... 25
CHAPTER 06............................................................................................................................ 29
6.1 REVIEW OF FIVE CORE COMPETENCES ............................................................... 29
4
6.1.1 Knowledge and Understanding of Engineering Principles ...................................... 29
6.1.1.1 Introducing latest maintenance strategies for Fuel Oil Treatment Plant (FOTP)29
6.1.1.2 Innovative solution for Active Noise Control (ANC)....................................... 31
6.1.1.3 Completion of running of GTs in synchronous condenser mode ..................... 32
6.1.2 Practical Application of Engineering Knowledge ................................................... 33
6.1.2.1 Inspect and propose suitable repairing methods for Compressor diaphragms . 35
6.1.3 Leadership and Management ................................................................................... 35
6.1.3.1 Introducing 5S Concepts to KPS ...................................................................... 35
6.1.4 Procurement Work ................................................................................................... 37
6.1.5 Communication and Inter-personal skills ................................................................ 38
6.1.5.1 Communication skills developed during CEB career ....................................... 38
6.1.5.2 Conducting Blood donation camp .................................................................... 39
6.1.5.3 Six side cricket match in every year ................................................................. 39
6.1.6 Professional Conduct ............................................................................................... 39
6.1.6.1 Familiar with Relevant Legislation in Respect of Health, Safety & Risk ........ 39
6.1.7 IESL –Mechanical Engineering Sectional Committee ............................................ 40
CHAPTER 07............................................................................................................................ 41
7.1
CONTINUES PROFESSIONAL DEVELOPMENT ACTIVITIES FOR CAREER
DEVELOPMENT ................................................................................................................ 41
APPENDIX A: Organization Chart Of Kelanitissa Power Station Of Ceb ................................ 43
APPENDIX B: Organization Chart Of International Precision Moulds And Tools(Pvt)LTD.... 44
APPENDIX C: Organization Chart Of Trinity Packaging(Pvt)Ltd. ........................................... 45
5
LIST OF FIGURES
Figure 1: Tile manufacturing process ....................................................................................................... 16
Figure 2: Overview of common maintenance strategies and techniques ........................................ 290
6
LIST OF ABBREVIATIONS
AMTM
: Asset Management-Thermal Mechanical
ANC
: Active Noise Control
AWS
: American Welding Standard
CE
: Chief Engineer
CEB
: Ceylon Electricity Board
CNC
: Computer Numerical Control
DGM
: Deputy General Manager
EEC
: Engineering Education Centre
EDM
: Electrical Discharge Machine
FOTP
: Fuel Oil Treatment Plant
FFT
: Fast Fourier Transform
GT
: Gas Turbine
ICB
: International Competitive Bidding
ISO
: International Organization for Standardisation
KPS
: Kelanitissa Power Station
KWS
: Kelanitissa Welfare Society
NAITA
: National Apprentice and Industrial Training Authority
NCB
: National Competitive Bidding
NDT
: Non Destructive Test
NERDC
: National Engineering Research and Development Centre
OEM
: Original Equipments Manual
PNC
: Passive Noise Control
PPE
: Personal Protective Equipment
PQR
: Procedure Qualification Record
PV
: Photovoltaic
RO
: Reverse Osmosis
SCE
: Shift Charge Engineer
SSS
: Synchronous Self-Shifting
TAN
: Total Acid Number
TAB
: Total Base Number
TEC
: Technical Evaluation Committee
UOR
: University of Ruhuna
WPS
: Welding Procedure Specification
WPQ
: Welders’ Performance Qualification
7
CHAPTER 01
1.1 INTRODUCTION
I have entered to the Faculty of Engineering, University of Ruhuna (UOR) in 2004, having
successfully completed the G.C.E (A/L) examination from Hungama Vijayaba National College.
I have followed the four year full time B.Sc. Engineering degree course in the university from
29th December 2003 to 27th September 2008 and obtained Second Class Honours Upper
Division Degree in Mechanical and Manufacturing Engineering.
Also, I had an opportunity of having three sessions of In-Plant training which has 12 weeks for
each session conducted by Engineering Education Centre (EEC) of the faculty via National
Apprentice and Industrial Training Authority (NAITA). I followed my first three months InPlant training at the Ruhunu Bus Company Limited, Tangalle workshop from 01.03.2005 to
20.05.2005 as an undergraduate trainee.
I obtained my second three months in plant training program at the National Engineering
Research and Development Centre (NERDC) from 30.04.2007 to 20.07.2007. There I obtained
training in three departments. They are Department of design, fabrication and consultancy to
industries, Department of agriculture and post-harvest technology and Department of renewable
energy.
I completed my third three months in plant training program at the Lanka Walltile (Meepe) Pvt
Ltd from 23.06.2008 to 12.09.2008. During this period, I understood the whole process of tile
production. I also learnt machines and equipment involved in production lines. I could obtain
HIGH achievement (out of HIGH / SATISFACTORY / MARGINAL) for my overall in plant
training conducted by EEC of the faculty.
During the final year of the degree, I completed the undergraduate project on “use of highfrequency sound wave generators to chase out bats from human habitats”. In this project, we
designed a high-frequency ultrasonic sound wave generator (Bat Chaser) to drive out bats from
human habitats. Sound frequency range that bats use for their navigation plays the most
significant feature of this project. Generally, they use 1 kHz to 150 kHz frequency in their day to
day life. This range was analyzed to determine the most suitable methods for chasing out bats.
The design was presented with major three parts; Detector, Controller and Emitter Circuits. The
Detector circuit was used to check the presence of bats in the region. The Controller part was
8
used for controlling the Emitter. Once the detector is activated, the controller sends signal to
emitter to emit high frequency sound waves which would effectively confuse the bats natural
sonar detection mechanism. By doing so we anticipated that bats would avoid living in such
environments and leave the buildings. As humans cannot hear the frequencies above 20 kHz,
such equipment with higher frequencies will not disturb the operation of other electronic devices
such as televisions and radios.
After graduation, I joined the Department of Mechanical & Manufacturing Engineering, Faculty
of Engineering, University of Ruhuna as a demonstrator since I had an idea to follow the higher
studies. However, since I got a better opportunity, I joined International Precision Moulds and
Tools (Pvt) Limited as a production Trainee. During that training period, I got hand on
experience on semi automated and fully automated CNC machines.
Meanwhile, I have started my Postgraduate studies at Faculty of Engineering, University of
Moratuwa. In year 2013, I completed my Master of Engineering (MEng) degree in
Manufacturing Systems Engineering. I did my MEng research on the area of condition
monitoring and the dissertation title was “study of fault diagnosis of machineries using vibration
and oil analysis”. My second employer was Trinity Packaging (Pvt) Ltd which is a private
company, producing different type of packaging items for food industries. In this company, I
was assigned to do overall maintenance of Injection moulding and Tube making machines.
Thereafter, there was an important milestone in my career. I got a valuable opportunity to join
the Ceylon Electricity Board (CEB) as a Mechanical Engineer on 15.02.2010. Since then, I am
working to the Kelanitissa Power Station (KPS) of CEB. This was a great opportunity for me to
uplift the maintenance of the power station, improving reliability and enhancing availability by
applying the knowledge and experience gathered from the private sector.
9
CHAPTER 02
2.1 SUMMARY OF RECOGNIZED TRAINING AND RESPONSIBLE
EXPERIENCE
2.1.1
Recognized Training Prior to Graduation (Vide Rule 5.8.1.2)
Total: 9 Months
Inclusive Dates
Place of Work
From
Ruhunu Bus
01.03.2005
To
20.05.2005
Signature
Duration
Position
Under Whom
(months)
3
Certifying
Officer
Undergraduate
Company
of
Trainee
Limited
Eng: A.K. Laksiri
Assistant Manager
(Engineering)
National
30.04.2007
20.07.2007
3
Undergraduate
Engineering
Trainee
Research and
Eng KYHD Shantha
B.Sc. Eng.(Hons),
CEng
Development
Centre
Director (Agriculture
(NERDC)
& Post Harvest
Technology)
Lanka Walltile
23.06.2008
12.09.2008
3
Undergraduate
(Meepe) Pvt Ltd
2.1.2
Trainee
Eng A.R.N. Divakara
B.Sc. Eng.(Hons)
Recognized Training after Graduation (Vide Rule 5.2.2)
Total: 3 Months
Inclusive Dates
Place of Work
From
International
07.09.2009
To
8.12.2009
Signature
Duration
Position
Under Whom
(months)
3
Trainee
Moulds and
Eng K.A. Amila
Engineering Manager
(Production)
Tools (Pvt)
Limited
10
Certifying
Officer
Production
Precision
of
2.1.3
Responsible Experience (Vide Rule 5.3)
Total: 87 Months
Inclusive Dates
Place of Work
From
Dept/Mechanic
01.01.2009
To
Signature
Duration
Position
Under Whom
of
Certifying
(Months)
04.09.2009
08
Officer
Demonstrator
al &
Dr.
Ambawatte.
Chithral
B.Sc. Eng.(Hons),
Manufacturing
MEng, PhD (AIT),
Engineering,
CEng
Faculty of
Head of the Dept.
Engineering,
Mechanical and
University of
Manufacturing
Ruhuna
Engineering,
University of Ruhuna.
Trinity
10.12.2009
12.02.2010
02
Packaging (Pvt)
Assistant
Maintenance Engineer
Engineer
Trinity Packaging
Ltd
(Pvt) Ltd
Kelanitissa
15.02.2010
15.07.2016
77
Mechanical
Power Station of
Engineer
Eng. A.I.A. Baduge
B.Sc. Eng. (Hon),
CEng.
Ceylon
Deputy General
Electricity Board
Manager (AMTM)
Eng. L.T.
Ameenudeen,
B.Sc. Eng, C.Eng.
Chief Engineer (KPS)
Responsible experience to the submission date 15.07.2016, 12 months, which equals to half of
the 24 months experience at CEB, would be counted as “Experience in lieu of Training”.
2.1.4
Exemptions (Rule 5.5)
No. of Months
(a) Recognized Training
12
(b) Responsible Experience
57
(c) Experience in lieu of Training
24
11
2.1.5
Break Down of Total Training and Experience
Description
Total
Duration Claimed (Months)
Duration
Training
Experience
9
9
0
8
0
2
3
3
0
24
12
0
Ltd]
2
0
2
Responsible experience [at CEB]
53
0
53
Total
99
24
57
( Months )
Recognized training prior to graduation
Recognized training after graduation [Department
of Mechanical & manufacturing Engineering at
Faculty of Engineering, Ruhuna]
Recognized
training
after
graduation
[at
International Precision Moulds and Tools (Pvt)
Limited]
Responsible experience in lieu of recognized
training [at CEB ]
Responsible experience [at Trinity Packaging (Pvt)
12
CHAPTER 03
3.1 RECOGNIZED TRAINING PRIOR TO GRADUATION
3.1.1 In-Plant Training at Ruhunu Bus Company Limited
Position
: In- Plant Trainee
Period
: 01.03.2005 to 20.05.2005
Nature of work
: In-Plant training as an undergraduate
Under Ruhunu Bus Company Limited, I was appointed to Tangalle depot. There are more than
40 buses in Tangalle depot and most of the maintenance activities of those buses are done at
depot. In general, this training period at the Tangalle bus depot enhanced my abilities to work as
a Mechanical Engineer by providing me the initial exposure, understanding and familiarization in
machine shop activities and workshop fabrications.
At the beginning of the training, I studied how to run a bus using a diesel engine. There were
many situations, I involved for repair activities such as running repairs on diesel engine,
overhauling of diesel engines and gear box, servicing and repairing injector, water pumps. During
this period, I got hand on experience of workshop practices such as Lathe and Milling machine.
There, I could study and have hands on experience in welding application which were being used
for maintenance activities of vehicles. I studied and practiced basic welding type such as electric
arc and oxy acetylene welding. In addition to that basic sheet metal works and sheet joining
methods were studied. The knowledge gathered during my training period at Tangalle depot built
up my confidence to work as a Mechanical Engineer.
3.1.2 In-Plant Training at National Engineering Research & Development Centre.
Position
: In- Plant Trainee
Period
: 30.04.2007 to 20.07.2007
Nature of work
: In-Plant training as an undergraduate
I obtained my second three months in plant training program at the NERDC from 30.04.2007 to
20.07.2007. NERDC is the premier engineering research and development centre in the country
for supporting industrial development and improving of living standards of the people. Also this
organization develops technologies that would help in the sustainable utilization of human and
material resources towards the economic development of the country. They are doing research
and development in the area such as, renewable energy, energy and environmental management,
13
electrical, electronic & mechatronics, design fabrication and consultancy to industry, civil
engineering, agriculture & post harvest and techno marketing. There, I obtained training in three
departments. They are department of renewable energy, design, fabrication and consultancy to
industries and agriculture and post harvest technology.
At the beginning of the training, I was appointed to renewable energy department. During the
initial weeks of my training period, I had an opportunity to study basic concept for renewable
energy. There were many ongoing research and development activities in the area of mini hydro
power, wind power, biomass energy application (Gasification system), cooking stoves and drying
systems and solar energy in the department. In the second week of the renewable department, I
involved to find out the performance of mini hydro turbine which was manufactured in china.
Details of the tested turbine were as below.
Type = Pelton
Rated RPM = 1500
Design net head = 52m
Designed electrical power = 5 kw
Design flow = 21 l/s
No of jet = 4
Impulse turbine was tested under different condition to find out the best efficiency of the
turbine. There were several variable such as, water head and flow, water direction (vertical &
horizontal), number of water jet. Different type of turbines and their application were studied.
Under the wind turbine, in NERD centre, I got opportunity to involve many projects such as,
wind powered water pumping system, wind power generation, calculation and design for wind
blade profile and wind blade manufacturing using fibre. Theoretically most efficient wind blade
profile is calculated and it is drawn in software. Then, it is manufactured using fibre. After that,
these new wind blades are tested in the field which was located in Suriyawewa area.
I learnt many things regarding solar power and related projects in this department. CentralizedGrid connected electricity generation systems, solar thermal, solar PV (Photovoltaic),
Decentralized- Photovoltaic, domestic lighting (Solar Home Systems and,
Solar Lanterns),
street lighting, and solar water pumping.
After first four weeks, I was appointed to department of design, fabrication and consultancy to
industries. There were fully automated CNC machines, EDM machine, lathe machines, milling
machines, shaping machines, drilling machines, punch and shear machines, sheet metal bending
machines, metal shearing machines, grinding machines in this department. So, this was a great
opportunity for me to earn hands on experience in the workshop with the above machineries.
14
(mainly machining operations such as turning, boring, drilling, slotting, grinding, planning,
threading, milling and knurling). Also, the different usage of each machine and available
operational features and the limitations were identified. Also, I learnt about different type of
tools which are used for these machines. I could also study the material identification method
using sand wheel grinding machine. I obtained experiences on mould, die and punch design,
manufacturing and repair, CAD/CAM, heat treatment, CNC machine operation and
programming. Another main area which I leant in this section was injection moulding. (injection
molding machines, mould design, mould storage, materials, injection molding cycle, different
types of injection molding processes and molding defects).
In last three weeks, I was assigned to department of agriculture and post harvest technology. I
involved with developing machines for food and agriculture sectors. I engaged with design,
fabrication and experiment of bio mass rice cooker which uses coconut shells as fuel, the action
of which is very similar to the electric rice cooker (It can cook 1 kg rice using 02 coconut shells).
I also, got lots of experiences associating to develop manual and hydraulic soil block machine,
vegetable cutting machine. I could observe and study various welding applications which were
being used for mechanical structural fabrications. Basic welding types such as electric arc
welding and oxy-acetylene gas cutting were studied and practiced.
The knowledge gathered during my training period at the NERD centre built up my confidence
to work as a Mechanical Engineer.
3.1.3 In-Plant Training at Lanka Wall Tile Meepe (Pvt) Ltd – Meepe, Sri Lanka.
Position
: In- Plant Trainee
Period
: 23.06.2008 to 12.09.2008
Nature of work
: In-Plant training as an undergraduate
Lanka Walltiles Meepe (Pvt) Ltd is the only wall tiles manufacturer in Sri Lanka who produces
and sells wall tiles to the local market as well as to the export market. Lanka Wall tiles PLC has
been producing and exporting high quality ceramic tiles for over thirty five years. The market
leader and premier ceramic wall tile manufacturer in Sri Lanka, is also a major contender in the
highly competitive international arena, supplying quality tiles to discerning markets. They have
the capacity to produce approximately 2.3 million square meters of tiles annually. A wide range
of tiles in a variety of colors, textures and sizes including special trim tiles and decorated tiles are
manufactured by the company today.
15
At the beginning of the training, I was assigned to production department where I learnt the
whole process of tile production such as raw material, batching, mixing & grinding, filter
pressing, spray drying, tile forming, drying, glazing, firing, quality control, labelling and packing.
During this period I obtained experience related to production planning and quality controlling,
how to achieve the targets optimising the machines. Concepts of Work-Study and Ergonomics
to obtain maximum output were also practiced.
Figure 1: Tile manufacturing process
During latter part of the training, I was appointed to maintenance department where I involved
with the maintenance activities of machines and equipments. I learnt the machines and
equipment involved in production lines such as spray drying equipment, shaping machine, air
powered diaphragm pump, clay agitating screen, glazing machine, conveyor equipment, motors,
high speed roller kiln, packing machine pumps and compressor. I also calculated the thermal
efficiency of kiln and prepared a report for the management. Different maintenances strategies
followed by maintenance department were also studied.
The knowledge gathered during my training period at Lanka Wall Tile Meepe (Pvt) Ltd built up
my confidence to work as a Mechanical Engineer.
16
CHAPTER 04
4.1 RECOGNIZED TRAINING AFTER GRADUATION
4.1.1 International Precision Moulds and Tools (Pvt) Limited
Position
: Production Trainee Engineer
Period
: 07.09.2009 to 08.12.2009
Nature of work
: Recognized training after graduation
This is a UK based private company and they have extensive experience in producing single and
multi cavity plastic injection moulds for the international medicine and automotive markets.
They offer full design and manufacturing capabilities and utilizing the high speed and fully
automated CNC machining, EDM, grinding machine and wire erosion technologies. During this
period, I got opportunities to have hand on experience on these machines, CNC machine
programming and sound usage of CAD software (AUTO CAD (2D & 3D)/SOLID WORKS).
Parts of moulds are machined according to drawings which are generated by the design section. I
attended on design and preparation of part drawings and assemble drawings. Coordinating
among workshop and design departments and planning the machining of parts of moulds
according to the deadline. Also, I engaged with heat treatment activities of steel which are used
for machining.
17
CHAPTER 05
5.1 RESPONSIBLE EXPERIENCE
5.1.1 Department of Mechanical & Manufacturing Engineering, Faculty of
Engineering,University of Ruhuna
Position
: Demonstrator
Period
: 01.01.2009 to 04.09.2009
Nature of work
: Responsible Experience
I carried out the laboratory experiments for undergraduate students (Thermodynamics,
CAD/CAM and Automobile). Also I engaged on delivering an Auto CAD software course for
government employees. I carried out ongoing workshop, projects and assisting design and
drawing classes.
5.1.2 Trinity Packaging (Pvt) Ltd
Position
: Assistant Engineer
Period
: 10.12.2009 to 12.02.2010
Nature of work
: Responsible Experience
My second employer was Trinity Packaging (Pvt) Ltd that is a private company, producing
different type of packaging items for food industries. In this company, I was assigned to do
overall maintenance of injection moulding and tube making machines, increase the availability
and reliability of the those machines, attending coordination/progress meeting for approval of
sample of packaging and quality issues with customers (Unilever (Pvt) Ltd, Hemas PLC and
Swadeshi Herbal Industrial (Pvt) Ltd), work scheduling, making reports on progress of ongoing
tasks and instructing, coordinating of working staff, overall maintenance of air conditioning
system of the factory, supervision of work shop & maintenance staff, planning the production
according to the deadline, maintaining good working relationship with customers, improve and
maintain the safety standards of the factory, coordinating the foreign & local customers in
regarding technical matters.
5.1.3 Ceylon Electricity Board
Position
: Mechanical Engineer
Period
: 15.02.2010 to 15.06.2016
Nature of work
: Responsible Experience
18
Ceylon Electricity Board (CEB) is the main power utility in Sri Lanka which provides quality
electricity to the nation using state-of-the-art technology while meeting acceptable environment
standards. CEB is the one and only organization which generate, transmit and distribute
electricity throughout the country. There are almost eight hundred Engineers in CEB and
approximately hundred out of them are mechanical Engineers.
5.1.3.1 Generation Division of CEB
One week orientation and induction training was arranged for newly recruited Mechanical
Engineers who were posted to Generation Division. The training programme included station
visits to Thermal Complex. In addition to above, I attended to group discussions and seminar
with officers of different branches at Generation Division to gain knowledge about the role of
each unit (in power generation) including Generation Projects, Mechanical Maintenance, Dam
Safety, Environment & Civil Structure Maintenance and Finance Branch of Generation Division.
During that one-week period I had an opportunity to visit all the power stations under Thermal
Complex of CEB naming Kelanitissa Power Station, Kelanitissa Combined Cycle Power Station
and Sapugaskanda Power Station. It helped me to have a good understanding about main
mechanical elements listed below involving in thermal power generation.

Steam Turbines

Gas Turbines

Diesel Engines
During that period, I studied about day-to-day operations of different types of thermal power
stations and maintenance of mechanical equipments. At the end of that one week period I was
posted to KPS of Thermal Complex.
5.1.3.2 Mechanical Engineer, Fuel System at Kelanitissa Power Station of CEB
(01.03.2010 to 31.12.2013)
Responsibilities and Duties:
I have joined CEB as a Mechanical Engineer Class (II) Grade (II) on 15.02.2010. I started my
career from the Power Generation section and I have been posted as Mechanical Engineer (Fuel
System) of the Kelanitissa Power station. Kelanitissa Power Station was commissioned in 1962.
It is located in Kolonnawa, Colombo and close to New Kelani Bridge road.
As a Mechanical Engineer of the power station, I was assigned following list of duties by Chief
Engineer at Kelanitissa Power station.
19
a) Fuel tanks (There are six fuel tanks with a capacity of 12000 m3 each in four tanks and 4500
m3 each in two tanks at KPS) & fuel transmission pipe lines.
b) New and Old Fuel Oil Treatment Plant (Veronesi and Wesfalia).
c) Fuel transfer pumps, valves, piping network from CPC (Ceylon Petroleum Corporation)
point to gas turbine inlet points and associated equipment and structures.
d) Oily water separator system, sludge disposal system and associated equipment.
e) Fire guard system (Tank farm fire water systems including foam system and station fire water
system and all type of fire extinguisher)
f) Water treatment plant.
g) All type of air conditioners.
h) Demineralised water tanks (02) & Town water tanks (03).
i) Inspection of AES water line.
The duties are specified as given below.
1. Supervision of staff assigned to particular section. This includes supervision of attendance,
make recommendations for increments and promotions, disciplinary actions and control of
overtime and leave.
2. Execution of maintenance and repair works of the plant and equipment. In this context
maximum utilization of resources and effective cost control are to be ensured.
3. Ensure that, all repair and maintenance works are carried out in line with work permit
procedure.
4. Formulation and execution of preventive maintenance programs including periodic
inspections and keeping relevant records and data.
5. Making the Shift Charge Engineer (SCE) aware in time of alterations and modifications
carried out in the existing system and issue specific instructions relevant to any changes.
6. To report immediately to CE (KPS) in respect of important issues such as major failures,
breakdowns and injuries.
7. Supervision of safety in the execution of work ensuring acceptable safety standards are
practiced.
8. Ensuring the availability of all materials, spare parts and tools etc as required or execution of
work in the section including all contingencies and also, in this respect preparing
specifications for foreign and local procurement and take initiatives in time.
9. Perusing log book and defect notifications maintained by the SCE for follow -up action in
time on any defects reported or revealed by observation and informing the SCE when
defects are rectified.
20
10. Supervision of cleanliness in areas where any work is executed by your section.
11. Advising the Store Keeper for maintaining minimum stock levels of spare parts and
materials, and carrying out periodic checks.
12. Purchasing of necessary safety items and first-aid items to the power station.
13. Conducting annual inspection/testing of pressure vessels, hoists, lifts, cranes and lifting
tackles according to the factory ordinance act no.45 of 1942.
14. To ensure a proper sufficient of spares, materials and labour for all work undertaken. There
should be no loss of time due to a lack of these resources.
15. To make local purchases when necessary, in consultation with the Chief Engineer.
16. To maintain all places of work and buildings in his charge in a state of cleanliness and good
repair at all times.
17. To maintain records as described including maintenance records.
18. To certify that all indented items received are in accordance with specifications.
19. Covering up duties of other Mechanical Maintenance Engineers when they are on leave.
20. Preparation of budget forecast estimates.
21. Supervision of the disposal of off -charge materials produced in day - to - day work.
22. Maintenance and protection of all drawings and manuals etc. relevant to fuel handling system
and their periodic verification.
23. Monthly verification of stores.
24. Training of staff.
25. All maintenance activities of civil section.
26. Any other duties assigned by CE (KPS).
In first few months, identification of the importance, their construction/design specifications
and special features of main elements in my section that is new and old Fuel Oil Treatment Plant
(FOTP), Tank farm, all type of air conditioners and fire system was done. Identification of the
importance, specifications and frequently occurring faults of main mechanical systems was done.
Identification, planning and handling of breakdown maintenance, preventive maintenance and
improvement maintenance was done. CEB rules and regulations before, during and after the
maintenance works such as isolation and permit to work request were practiced during that
period. Further to that importance of planning spare parts, time and labour for a particular
maintenance job was identified. Operation and Maintenance (O&M) manuals and reference
drawings were referred to obtain clarifications and detailed specifications.
21
The machine shop was used to cater the requirements arising in maintenance works. Mainly
machining operations such as turning, boring, drilling, grinding, threading, milling and knurling
performed on machine parts in order to rectify the breakdown/preventive maintenance. CEB
administrative procedures (leave, disciplinary, etc…), schemes (pension, medical, EPF, ETF,
etc...), CEB Financial and Administrative Circulars, CEB stores management processes were
studied during that period.
The KPS is one of the biggest thermal power stations which generates 195 MW electrical power
to the national grid especially covering the Colombo area in a blackout situation. There are five
gas turbines under the open cycle category having a capacity of 115 MW in one and 20 MW each
in four machines. When all gas turbine machines are running, 1.2 million litres of diesel are
required to combust per day. Further, this amount can be increased up to 2 million litres per day
when naphtha oil is not available to the Kelanitissa Combined Cycle Power Station which has a
capacity of 165 MW. Therefore, the above mentioned diesel requirements are prepared from
Fuel Oil Treatment Plant (FOTP) that consists Veronesi separators for diesel purification.
Maintenance activities of FOTP are one of the main responsibilities as a mechanical engineer in
fuel system.
The first project assigned was, renovating bottom plate of untreated diesel storage tank which
has a capacity of 12000 m3 installed by a company from United Kingdom in 1980. During this
project, I learnt different technical and non technical skills and speculations. The following
paragraphs describe how I acquired the knowledge and necessary skills throughout the career.
One of the critical problems of diesel tanks is the corrosion of bottom plates of the tanks as
diesel is mixed with water. It is very important to determine the tank bottom integrity which is
necessary to prevent leakage of diesel. There are many reasons for the failures in tank bottom
that can be considered in the decision to line repairing or replacement. I carried out maintenance
activities of diesel tanks in accordance with API 653 (American Petroleum Institute) which is a
widely used international standard for tank inspection, repairing, alteration, and reconstruction.
One of the senior chartered engineers who is vastly experienced in that area worked as
consultant in this project. As a subordinate, I had the pleasure of working under his immense
capacity and techniques which dramatically helped to improve my knowledge in the field. API
653 includes information on the time duration for internal and external tank inspection. These
intervals have been established based on the bottom thickness of the tank, corrosion rate and
integrity.
22
I followed “tank out of service inspection check list” during the inspection which provided all
the necessary steps for carrying out proper internal tank inspection. To start internal inspection
firstly, it was required to clean and gas-freed the tank. Diesel tank was emptied and washed out
using high pressure water jets. That was repeated several days. Gas freed process was inspected
by authorized inspector and issued the gas free certification having achieved required level of
cleaning inside the tank. I entered to the tank for the inspection. The bottom plate was visually
inspected and it was observed that there are holes on the plate. Those holes which didn’t pass
through the bottom plate were about 2 to 6 mm in diameter. However, there were not any
corroded holes, mechanical dent or local dishing to repair within critical zone of the tank. These
small holes could be due to stay water layer on bottom plate for long period and then corrode
the bottom plate. According to API 653, Ultrasonic thickness inspection (UT test) was carried
out for measuring bottom plate thickness (Grid system was drawn on the bottom plate). A
drawing was prepared for tank bottom plate with measured thickness (AutoCAD software was
used). According to the equation given by API 653 standard, the minimum acceptable bottom
plate thickness of the tank was calculated.
More than 90% of total bottom plate area was in good condition and measured tank bottom
plate thickness was higher than minimum required thickness. Therefore, it was not required to
replace the entire bottom plate. Since these small holes were not large enough to repair using
direct welding (if small holes are welded directly, it is difficult to close them properly due to air
trapping). It was decided to cover the holes by new metal pieces same as bottom plate.
Rectangular shape metal pieces were used to cover the holes. Also, they were welded as lap weld.
Proper welding process is very important to prevent any oil leakage. Therefore Welding
Procedure Specification (WPS), welders and welding operators were qualified in accordance with
Section IX of the ASME code. Procedure Qualification Record (PQR) was used to verify the
WPS. The WPS is qualified by welding procedure qualification test coupons. The variables and
tests used were recorded on a PQR. Finally, the performance of the welders was verified by
welding performance qualification test coupons. The variables and tests used with the
particular variable ranges qualified were recorded on Welders’ Performance Qualification (WPQ)
record. Two welders were qualified for that Work. In that process, all relevant parameters such
as welding current and voltage, welding speed, characteristic of electrode, temperature were
presented in welding PQR. The success of welded work pieces were tested for bend test and non
destructive test or observe cross section of the welded work pieces as prescribed by PQR.
Further, low hydrogen welding electrode (E 7018) was used for the application as it prevents
23
issues of cracking on the welded line. And, those were stored in oven (120 0C – 150 0C) to
prevent moisture absorption.
After completing tank bottom plates, entire welded lengths were examined visually for any
potential defects and leaks. In addition to visual inspection, they were examined using liquid
penetrate technique and magnetic particle testing over its full length. It was very easy to carry out
those testing techniques since I had adequate training for non destructive testing at Atomic
Energy Authority, Sri Lanka which is the main professional body for conducting training
programs for non destructive testing. After verifying that there is no any leakage on the bottom
plate, the bottom plate was painted.
Painting of bottom plate plays a significant role here. Widely used methods for surface
preparation of bottom plates for painting are sandblasting and power blasting. Power blasting
technique was used by considering several factors. ISO 12944 part 1 to 7 provided guideline for
the selection and applying paint for this kind of application. The tank bottom plate was blast
cleaned to Swedish standard SA 2.5, near white finish (BS4232, Second Quality). All the blast
cleaned surfaces were blown off with compressed air to remove all traces of blast cleaned
products before painting. Primary painting for bottom surface was applied as soon as possible
after cleaning, but not more than 4 hours after cleaning. For monitoring and analyzing purpose, I
obtained number of parameters (dry bulb temperature, wet bulb temperature, wet film
thicknesses of each paint coating, and finally dry film thickness of each paint coating) during the
painting process. I undertook several training courses of painting which were conducted by
Dockyard General Engineering Services PLC which is the largest service provider for designing,
building, repairing and painting ships and tanks in Sri Lanka. Therefore, it was easy to select
suitable paint system for tank bottom plates. After painting the bottom plate, tank was
commissioned and released to operation.
Through this project, I gained experience and specialized in following engineering practices; tank
repair, related standards, prepare technical documents, preparation of drawings, inspection
checklist, procedure qualification records, prescribe welding procedures and qualifying
methodology (both welding procedure and welders) according to the ASME standard and API
653 standard, select suitable paints and apply according to standards (ISO 12944). Other than
that, I referred text books, such as modern welding technology, machines design.
24
Annual Plant and Equipment Test According to the Factory Audience Act 1942 No 45:
There are more than hundred equipment belongs to cranes, hoists, lifts, pressure vessels and lifting
tackles categories which are essentially tested once in every half an year/year according to the Factory
Audience Act. The plant and equipment were tested with an external inspector for last five years.
5.1.3.3 Mechanical Engineer, Gas turbine at Kelanitissa Power Station of CEB
(01.01.2014 to 15.07.2016)
Responsibilities and Duties:
After four years in fuel system, I was appointed as mechanical engineer for gas turbine at same
power station on 01.01.2014. As a Mechanical Engineer (GT) of the Power Station I was
assigned following list of duties by CE (KPS).
As Mechanical Maintenance Engineer in charge of Frame V gas turbine section, I was
responsible for the all maintenance of:
(a). Turbine and compressor units (including combustion system, exhaust system, bearings,
couplings, IGV, Bleed valves, Heat exchanges, filters, piping systems, structures and
associated equipment).
(b). Diesel engines.
(c). All pumps, valves and piping of the lubrication system, hydraulic system, cooling
water
system, air systems, and fuel system.
(d). Accessory Gear Box Load and Gear Box including Synchronous Self-Shifting (SSS) clutch.
(e). Torque Converter and Hydraulic Ratchet System.
(f). Mechanical structures and enclosures of the Accessory / Turbines / Load Gear
compartments.
(g). Inlet air filter house.
(h) All maintenance of the KATO –NKH mobile crane 20 ton.
The duties are specified as given below,
1. Execution of maintenance and repair works of plant and equipment. In this context
maximum utilization of resources and effective cost control are to be ensured.
25
2. Supervision of staff assigned to your section. This includes supervision of attendance,
make
recommendations for increments and promotions, disciplinary actions and control of overtime
and leave.
3. Ensuring all repair and maintenance works are carried out in line with work permit
procedure.
4. Formulation and execution of preventive maintenance programs including periodic
inspections and keeping relevant records and data including equipment history records.
5. Making SCE aware in time, of alterations and modifications carried out in the existing
system and issue specific instructions relevant to any changes.
6. Reporting immediately to CE (KPS) in respect of important issues such as major failures,
breakdowns and injuries.
7. Supervision of safety in the execution of work ensuring acceptable safety standards are
practiced.
8. Ensuring the availability of all materials, spare parts and tools etc as required for execution of
work in the section including all contingencies and also, in this respect, preparing specifications
for foreign and local procurement and take initiative in time.
9. Perusing log sheets and report books maintained by the SCE for follow – up action on any
defects reported or revealed by observation. Keep the SCE informed when defects are rectified.
10. Supervision of cleanliness in areas where any work is executed by your section.
11. Advising the Store Keeper for maintaining minimum stock levels of spare parts and
materials, and carrying out periodic checks
12. Covering up duties of other Mechanical Maintenance Engineers when they are on
leave.
13. Preparation of budget forecast estimates.
14. Supervision of disposal of off-charge materials produced in day to day work.
15. Maintenance and protection of all drawings and manuals etc relevant to Frame V Gas
Turbine Mechanical Maintenance Section and their periodic verification.
16. Monthly verification of stores.
17. Carrying out periodic efficiency and performance tests in the plant and equipment and
maintenance of relevant records.
18. Submission of monthly progress and evaluation reports of work executed by your section.
26
19. Training of staff.
20. Any other duties assigned by CE (KPS) from time to time.
In first few months, construction/design specifications and special features of main elements of
gas turbines such as air filter house, Inlet Guide Vane (IGV), compressor, combustion chamber,
transition piece, liner, nozzle and diaphragm, turbine blade, journal bearing, SSS clutch, diffuser,
exhaust duct, accessory gear box (drives are taken from appropriate shafts for auxiliaries
hydraulic and lube oil pump, atomising air compressor, fuel pump, cooling water pump),
hydraulic ratchet gear, lube oil pumps (main oil pump, auxiliary and emergency pump, A.C.
pump) were studied. Main supporting system of gas turbine such as lubricating system, control
oil system, hydraulic oil system, fuel system, cooling system (water & oil), combustion system,
starting system, air system and ventilation and heating system were studied.
A new well was constructed to supply clean water for applications such as for FOTP, Gas
Turbine (GT) auxiliary systems and daily use.
Since the KPS is located with close proximity to Kelani river, water requirements at KPS is
partially fulfilled by pumped water and the remaining is supplied by national water board which
is one and only urban water supplier in Sri Lanka. To produce town water, national water supply
board use the same river water. This town water is mainly used for drinking purpose, FOTP, GT
auxiliary systems and day today human activities. Town water which is used for FOTP, GT
auxiliary systems is cleaned through demineralized water preparation system. However, when
there is more salt in town water, this system cannot remove salt completely. Town water usage
per month is about 5,000 m3 that makes cost about four million per year. Water that is pumped
from Kelani river is used for fire hydrant system. River water requirement is about 6,000 m3 per
month. Due to the close proximity to the sea, both river and town water consist significant
amount of salt which cause to increase the conductivity particularly, in dry season (in dry season,
sea water flows upward through the river). High conductivity water cannot be used for FOTP
and gas turbine auxiliary systems.
As a solution for this problem, reverse osmosis (RO) water filter was analyzed to install at KPS.
However, I came to know that the reverse osmosis system is not working properly at Kelanitissa
combined cycle power station (It is another CEB thermal power station that is attached to KPS.
They also use water from national water board and Kelani river) due to high salt concentration in
dry season. This system has only two stages. Whenever, number of stages of RO system is
27
increased for having pure water, initial cost and maintenance cost of OR system increase. Finally,
it was decided to construct a new well for solving this problem since ground water body of KPS
land is geologically qualified.
If water can be supplied from the new well, there are key benefits; firstly, we can have low
conductivity water for FOTP and auxiliary systems of GTs in dry season in Sri Lanka. Further,
we can cut down the water bill. Initially, the higher management was informed about this project
and I was assigned to prepare the project proposal including payback period. Within few days,
the permission was granted to construct a new well at KPS. It took about 2 months to complete
the work. It was planned to obtain at least 100 m3 water per day from new well. Finally the
supply capacity was measured. The new well fulfilled the required water capacity and quality.
It was planned to pump and store water in the steel tank which was available on the upper floor
of the building. Capacity of the steel tank is about 45 m3 and it is located 200 m away from the
well. The height of the building was about 20 m. Subsequently, the piping system and control
system was established. For that total head (static head (suction head + delivery head) + major
losses head (friction loss + component loss)), desired flow rate, suction lift, and characteristics of
the fluid were identified as important parameters. Static head was measured. Desired flow rate at
stored tank was measured by considering water demand of KPS (10 m3/h). Friction losses were
calculated using Darcy’s formula (velocity of the fluid within the pipe, viscosity of water and pipe
surface roughness were used) and component losses were taken from manufacturer’s component
manual. The total head, suction lift and flow rate are dependent of the piping system and the
pump’s characteristics. The piping system and the pump interaction were analyzed to determine
the operating point of the pump, flow rate and pressure. The pump cannot independently
control these parameters. I had to refer pump characteristic curves under different pump
manufacturers to reveal the performance of the pump and the allowable operating ranges.
Therefore, suitable pump (Three Phase, Centrifugal Pump) was selected by analyzing pump
characteristic curves (Net Positive Suction Head (NPSH), Efficiency, Head and power against
flow rate) and other important parameters. The best operating point of the system was also
analyzed. Two float switches were used for both water tank and well to decide the operation
point of the motor.
With this project, I could save Rs 1,500,000.00 water bills per year and solve the problem of use
of high conductivity water during dry season.
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CHAPTER 06
6.1 REVIEW OF FIVE CORE COMPETENCES
6.1.1 Knowledge and Understanding of Engineering Principles
6.1.1.1 Introducing latest maintenance strategies for Fuel Oil Treatment Plant (FOTP)
As a mechanical engineer in Fuel System at KPS, I take technical decisions and judgments on
work and its efficiency, reliability and financial ability. One of the major responsibilities was to
maintain FOTP which comprises six separators to purify auto diesel for gas turbine. Each of
them has a purifying capacity of 25 m3 per hour. Daily diesel requirement to run all the gas
turbines is 2000 m3 which is prepared using those separators. The major focus of the industry is
to improve the machine reliability which increases the maximum working life of machinery and
also minimize maintenance and operating costs. To achieve this, it was necessary to establish a
maintenance monitoring program to regularly assess the machine condition. Corrective and
Preventive Maintenance strategies have been prioritized in Ceylon Electricity Board. Separators
are subjected to preventive maintenance strategy for long time as a practice.
MAINTENANCE
PLANNED
MAINTENANCE
UNPLANNED
MAINTENANC
E
MAINTENANCE
PREVENTIVE
MAINTENANCE
VIBRATION
MONITORING
OIL
ANALYSIS
CORRECTIVE
MAINTENANCE
PREDICTIVE
MAINTENANCE
WEAR DEBRIS
MONITORING
VISUAL
INSPECTION
PROACTIVE
MAINTENANCE
PERFORMANCE
MONITORING
TEMPERATURE
MONITORING
Figure 2: Overview of common maintenance strategies and techniques
Preventive maintenance cycles are carried out at regular intervals which is shorter than the
expected time between failures. It is common to choose the intervals to be such that no more
than 1–2% of machines will experience failure in that time. This does mean that the vast majority
29
could have run longer by a factor of two or three. It is clear that we replace spare parts which
have extra working life span to run. And, it is a kind of wastage of resources. The annual cost of
purchasing spares from Italy is about Rs 20,000,000.00 for six machines. Therefore, I decided to
apply predictive maintenance strategy for these separators instead of preventive maintenance
strategy.
The Predictive maintenance strategy was included in the maintenance schedule of separators
since 2012. Since the potential breakdown of a machine is predicted through regular condition
monitoring, maintenance is carried out at the optimum time under this strategy. Instead of
relying on time-driven average machine life statistics to schedule maintenance activities, I
predicted the time of failure by monitoring the actual mechanical conditions of machines. Such a
system determines the equipment's health and act only when maintenance is actually necessary.
There are several techniques to predict the condition of a machine. Vibration analysis, current
monitoring and oil analysis were implemented to predict the condition of the separators.
SKF GX series Microlog Analyzer is used to collect the vibration level of the separators. This
analyzer is very advanced equipment which gives the vibration in all three parameters
(acceleration, velocity, and displacement) at moment. This is a very good reliable machine which
is used in many engineering fields to analyze the condition of machines. Vibration level of the
separator was monitored throughout running period in accordance of ISO 10816 guide lines and
diagnosis charts supplied by SKF. To measure vibration, several standard measurement
techniques are used. Basically, overall vibration and spectrum of the vibration is analyzed.
Overall vibration is the total vibration energy measured within a frequency range. By analyzing
Fast Fourier Transform (FFT) spectrum, condition of the separators can be predicted. If a
machinery problem exists, FFT spectrum provides information to determine the location of the
problem, the cause of the problem and with trending how long until the problem occurs at
certain frequencies. FFT spectrum was analyzed by looking at the amplitude changes in certain
frequency ranges. FFT spectrum allows to analyze vibration amplitudes at various component
frequencies on the spectrum. In this way, I can identify and track vibration occurring at specific
frequencies. Therefore, this information was used to diagnose the excessive vibration.
Lubrication oil analysis is very effective diagnostic programs that can signal a problem long
before vibration analysis confirms it. The lube oil is analyzed in a very sophisticated laboratory,
and the findings are recorded. This is a standard practice with most laboratories, and it greatly
30
helps the analysts to forewarn others of future problems. Many types of abnormal wear can exist
inside a piece of machinery. However, there are few primary sources of the wear. Problems
related to the oil itself may contribute to wear when the lubricant has degraded or become
contaminated. Machine condition also can contribute to the generation of wear if a component is
misaligned or improperly balanced. Improper use of the equipment, such as overload or
accelerated heating conditions, also can generate wear. This technique is capable of providing
important information about the health of the lubricant, interfacing of the machine with its
environment, and the health of the rotating machinery itself. Standard analysis normally includes
oil properties such as viscosity, Total Acid Number (TAN) or Total Base Number (TBN),
apparent pH value, fuel content, water content and flash point. These separators are fitted
through a gear box. Oil sample from gear box is analyzed to predict the condition of machines
every two weeks.
The separator is run using 30 kW induction motor and the power consumption of the motor is
measured while measuring the vibration. If there is any sign of poor condition of the machine,
power consumption of the machine could be increased with time. The analysis of power
consumption of the motor helps to predict the condition of the machines.
Results of the vibration, oil and current analysis were used together to optimize the conditions of
the machines. All three techniques were done as off line method. With those three analyzing
techniques, I was able to save about Rs 2,000,000.00 per year increasing time interval of MI, MO
and MR. Over many analyses, those reports serve as a trend analysis database for those
machines. This is a kind of mini research project to analyze the failure of a machine with various
techniques.
6.1.1.2 Innovative solution for Active Noise Control (ANC)
I am working as a researcher on the topic of ANC for enclosed Gas/Steam turbine power
generating plants in generation division of CEB. There are only two engineers who are working
on this research and Eng. A.I.A. Baduge (DGM-AMTM) is working as supervisors for this
research project.
ANC is a method for reducing unwanted sound by the addition of a second sound specifically
designed to cancel out the first. Basically a noise-cancellation speaker emits a sound wave with
the same amplitude but with inverted phase (i.e. anti phase) to the original sound. I studied the
31
legal requirements & Safe audible levels for employees who are engaging with high noise with Sri
Lanka - National Environmental Regulations for noise controlling. Primary objectives of this
research are noise induced hearing loss reduction in operation and maintenance staff of CEB
thermal power plants, reduce health risk, reduce fatigue, reduce speech interference and improve
work comfort of operation and maintenance staff of CEB thermal power plants. It is expected
that in enclosed spaces, noise reduction/control can be achieved via multiple speakers and
feedback microphones. Our research focuses the optimum method for ANC for enclosed
gas/steam turbine plants. Identification of knowledge gap in the research area is covered by
comprehensive literature review. As well as, we studied both Passive Noise Control (PNC) and
ANC. Actual noise levels of the power plants are measured by mean of Fast Fourier Transform
(FFT) analyzer. Collected data can be analyzed using Sound Analyzing Software. Primary
experimental model is made to test the one dimensional ANC. Using the performance of this
model, issues that can be arise for the 3D ANC model. Based on the findings of primary
modelling, 3D secondary modelling is to be done. In this case, developing new algorithm was the
main objective.
6.1.1.3 Completion of running of GTs in synchronous condenser mode
Frame v GTs (04) were used for generating active power mode since they were installed (1980).
Two of them were used for generating reactive power mode whenever the system requires the
reactive power. However, remain two were not used in synchronous condenser mode since they
were installed. (In electrical engineering, a synchronous condenser is a device identical to
a synchronous motor, whose shaft is not connected to anything but spin freely. Its purpose is not
to convert electric power to mechanical power or vice versa, but to adjust conditions on
the electric power transmission grid. Its field is controlled by a voltage regulator to either generate
or absorb reactive power as needed to adjust the grid's voltage, or to improve power factor. The
condenser’s installation and operation are identical to large electric motors and generators). After
commissioning of coal power station, system requires more reactive power than before. Therefore,
system control unit of CEB asks remain two GTs to run in synchronous condenser mode to full
this gap since 2013. However, engineers who had responsible to do it during that period reluctant
to run above mentioned two GTs in synchronous condenser mode since they were not ran for
long time. This matter was in rest for two years and came back again to discuss in mid of 2015
when I am working in this section. Then, I deeply studied main critical components which play
main role in synchronous condenser mode. SSS clutch is the one of main components that should
function properly to run in synchronous condenser mode. I deeply analyzed all relevant details of
32
SSS clutch that was in GTs. Function of the SSS clutch was checked. (Started the GT up to 5100
rpm and check generator side and compressor side are reach 0 rpm at same time or not. When GT
is running at 5100 rpm, the speed of generator side is 3000 rpm. If they do not reach 0 rpm in
same time, SSS clutch is working properly). After confirming that SSS clutch is working properly, I
informed to operation staff to run the GTs in synchronous condenser mode. We could run these
two GTs with in a shorter period of time like 1 ½ months period.
6.1.2 Practical Application of Engineering Knowledge
6.1.2.1 Generator Bearing installation and commissioning of frame v GT
Major inspection of Gas Turbine 01 (GT 01) was started in mid of 2012. Generator bearings of
GTs were maintained by electrical engineer since these were installed. All the mechanical
maintenance activities of GT 01 were handled by senior mechanical engineer, U.K.L.
Chulakeerthi. During this major inspection period, All Non Destructive Testing (NDT) of
compressor and turbine blades, transition pieces, liners, bearings and rotor alignment were done
by me with the supervision of U.K.L. Chulakeerthi. After few months, all mechanical and
electrical maintenance activities of GT 01 were completed except replacement of generator
bearing. Electrical engineer who maintains this generator bearing was reluctant to complete
remain part since they do not have a new bearing for installing. Cost for purchasing this bearing
is about seven million and lead time is about three months to import from Original Equipment
Manufacturer (OEM). Therefore, chief engineer assigned me to take remedial action for
generator bearing of GT 01 which was pending to complete for few months. All available used
generator bearings and shaft of GT 01 were inspected and made following observations,
•
Shaft was scratched with thermal patches to a level which can initiate fatigue failures.
•
Bearing was worn out with scratching marks and shown the shaft was not inline.
•
Alignment readings were different from standard readings.
•
Measurements were taken for ordering new bearing in future.
Since there are no available spare bearings or at least used ones in acceptable levels following
rectification measures were taken.
•
Ultrasonic testing was done to investigate the bonding quality of previous generator
bearing.
•
Shaft was polished and eliminated all undulations and waves which are possible to initiate
scratches in bearing shell again.
•
Bearing shell were polished, effectiveness of the dents were removed in order to avoid
initiation of damages on surface of the shaft.
33
•
Alignment was brought to clear levels as specified.
For future maintenance and performance following steps should followed,
After re-commissioning, this bearing should be reopened and inspected after one-week
operation. This step should be followed after one month and three months consecutively.
Thereafter, smooth operation of generator bearing can be confirmed. During this test period
close supervision of operation staff is required to monitor vibration levels of bearings and
operation of the GT 01.
6.1.2.2 Fabricating a steel structure according to the ALSTHOM standards for
Dismantling and reassembling of the GEC ALSTHOM Generator of Fiat Avio TG 50D5
115W.
Dismantling and reassembling of the GEC ALSTHOM Generator by fabricating a steel structure
according to the ALSTHOM standards at the second major inspection of Fiat Avio TG 50D5 115W
(GT-07) gas turbine during the period from 05/04/2012 to 27/03/2013. Project cost was 984 million.
After 100,000 running hours of above mentioned GT, second major inspection was started to carry
out the all necessary maintenance activities. I was assigned for above mentioned job as one of the
main supporting job of this inspection. Its scope covered most interesting topics in Mechanical
Engineering. According to the scope of the job, I had to fabricate a steel structure according to the
ALSTHOM standards for Dismantling and reassembling of the GEC ALSTHOM Generator of Fiat
Avio TG 50D5 115W.
Project was started with design drawings supplied by GEC ALSTHOM. During this stage of the job, I
had to find the steel structure in the market instead of steel sections provided by GEC ALSTHOM
due to market unavailability. At this moment, I did calculations for assure reliability of my designed
steel sections comply with their requirements. After planning works, I had to propose suitable welding
methods for each component covered in my scope. Hence, welding joints shall withstand to weight of
the generator rotor. Necessary welding methods and other required details obtained from British
standards and American Welding Standards (AWS) (I.e. BS 5135 and AWS D1.1). According to
standard practice, WPS generated and it was checked at workshop. Related parameters, such as
welding current values, pre temperature values of work pieces and welding rods recorded and
presented in specified welding procedure PQR. The success of welded work pieces were tested for
visual test, bend test and or liquid penetrant test or observe cross section of the welded work pieces as
prescribed by PQR. After qualifying welding methods, Welders were qualified and issued them a
certificate by following AWS standards (Welder qualification Record – WQR). During the fabrication
34
process I followed up designated workshop practices. Standard practices means follow tolerances
given in design, prescribed weld methods are using in the work, proper material handling and storing
methods are using etc. After the welding work, I followed up transporting, handling; erecting and
commissioning works are in order to standard practices. Prior each an above works related method
statements were developed by considering related standards and practical conditions. During the
projects managed by myself, I acquired various technical and non-technical skills and specialisations.
6.1.2.3 Inspect and propose suitable repairing methods for Compressor diaphragms
Next part of my job for second major inspection of Fiat Avio TG 50D5 115W (GT-07) was to
inspect and propose suitable repairing methods for Compressor diaphragms. According to the scope
of the job, initially, all diaphragms were cleaned. All uncoated surfaces were thoroughly cleaned by
dust blasting with 100 – 200 mesh aluminium oxide. Coated surfaces were cleaned with warm water
and soap. The major overhaul was including inspection of all compressor diaphragms visually and Dry
penetrant inspection for the parts which suspects exits. Vanes were inspected for damage, cracks and
nicks. Visual inspection and magnification lens were used. Tap test was applied to each vane. Vanes
were taped with a small ball peen hammer. A light tap cause a good vane to ring with a natural
resonance. A cracked vane had a dull sound. Examinations of all welds were made over an area
including the weld and base metal extending for at least 15 mm each side of the weld. Inspect welds
and other suspect areas for defects such as cracks and porosity. Most damage to the stator blades can
be caused by foreign objects entering the compressor. According to the criteria given in the manual,
blades were accepted/rejected and repaired.
6.1.3 Leadership and Management
6.1.3.1 Introducing 5S Concepts to KPS
I was appointed as 5S Officer of the station by Chief Engineer. Appearance of the plant was not
sufficient enough compared to other power plants in CEB. The requirement of a proper
housekeeping method such as Japanese 5S concept was emerged. Therefore, I decided to
improve quality, appearance and safety of the plant by implementing 5S concept at KPS as one
of the main thermal power station in CEB. There were several challenges on implementation and
sustenance. As the initial step of implementation, I decided to conduct an awareness program at
KPS to make aware the employees (210 employees including 10 engineers) through a guest
lecture by hiring an expert resource person. Subsequently an industrial visit to a power plant
where 5s concept has been implemented was arranged. With those, our employees got lot of
35
motivation and enthusiasm to implement and follow the 5S concept within the work
environment.
Proper action plan maintains the implementation of 5S. Therefore, I prepared an action plan for
this. In this action plan (It is an excel sheet), which includes about 125 actions, time frame to
complete them and money allocation. Some of these actions are leading to a method for
removing unwanted items (Sort – Seiri). I prepared 5S promotion posters and introduced
labelling method using different colour. Furthermore, a special day for seiri was allocated.
A method was prepared for proper arrangement, (Straighten-Seiton). Mission and vision of the
organization were exhibited in every workshops and office. Every hall, office rooms, almary,
cupboards, fan, bulb, switch, and telephone cables were numbered. Safety team was appointed
for improve the safety of employees. Board for writing accident was set in every workshops and
machine shops. Different colour codes were introduced to identify files, books, pipes. Every
section was named, set named boards. Roads and areas where used for vehicle parking were
named and coloured. Hazarded areas were labelled. First aid boxes were provided for every
section. Colour symbols were used to identify computer parts. Walking directions were drawn on
the stair cases, workshops, machine shops, stores and office.
A method was prepared for proper cleaning, (Shine –Seiso). It includes prepare a document for
cleaning and a check list. Cleaning jobs were allocated. 5-10 minutes on everyday was allocated
for cleaning in every working place. Officers for cleaning inspection were appointed. Garbage
such as polythene, plastics, glass and all other were categorized and arranged proper methods to
dispose separately. Some of them were converted to compost which can be used as fertilizer for
garden.
A method was prepared for proper purity, (Standardize–Seiketsu). Boards with Statement (“Save
Electricity, Water and Telephone”) were exhibited. Operation team for standardize was
appointed. Suggestion box for all sections and a person for 5S coordination were allocated. A
method was prepared for proper commitment (Sustain- Shitsuke). I prepared boards which
inform everybody that “5S is running here”. An environment protection team was appointed. A
policy was prepared for safety, health and training. First aid training was conducted for all
employees. It was decided to conduct a 5S competition in every year. 5S meeting was arranged to
discuss all issues in every month. This concept was well adopted in my workplace under my
coordination. This project gave a huge amount of non-technical knowledge and experience
through the job.
36
With implementing 5S concept, it covers health, safety of all employees and it follows the
environmental responsibilities. Money was allocated to do all these things. I engaged to improve
the health and safety of employees and plant. Additional rules and regulations were introduced to
use personal protective equipment (PPE) to minimize the work place accidents. Furthermore,
risk assessment and analysis were made a compulsory activity for each and every activity within
the work place. Emergency showers and eye wash baths were set in relevant areas. Safety notice
boards were displayed in everywhere.
All those projects and activities gave me a broad knowledge and experience on non-technical
activities required to be a successful mechanical engineer.
6.1.3.2 Procurement Work
As a mechanical maintenance engineer, I should procure all goods and services required for
maintenances activities handled by me. After the initial investigations were carried out tentative
materials plans were prepared for the relevant year. Then accordingly master procurement plan
was prepared. The National Procurement Guidelines 2006 was referred for the procurement
planning and implementation. Procurement of materials had to be done through competitive
bidding internationally (International Competitive Bidding, ICB) and locally (National
Competitive Budding, NCB) as the case may be. Since some sets of materials are usually sold by
same suppliers they were bundled together for each tender. Some materials had to slice for
several packages for several reasons. Availability of stores, to encourage large and small suppliers
to bid and time taken for procurement process are some of them. Domestic preference was
given to encourage local manufacturers.
I served numerous number of Technical Evaluation Committees (TEC) as a convenor while I
was doing my duties as a Mechanical Engineer. It gave me thorough experience on problem
solving, analysing and evaluation adhering to the Government Procurement Guide Line. In order
to that, it gave me good hands on experience in major elements of a procurement process such
as preparations of specifications and bid documents, invitation of bids, bid opening, bid
evaluation, TEC reporting and related legal/technical aspects. Usually I served as the convener
of the TEC so that it gave me a good opportunity to share experience from senior engineers and
non-engineering professionals in the industry.
37
I have gained lots of experience on non-technical matters during my career as a mechanical
engineer in CEB. The following paragraphs explain in details the information on non-technical
areas including the level of knowledge and understand that I need to have to be successful as a
mechanical engineer.
It is required to prepare a budget for all the expenditures (CAPEX – Capital Expenditure and
OPEX- Operational Expenditure) for the maintenance activities in my section for every year.
When I was working as a mechanical engineer for Fuel System at KPS, I allocated money for all
expenditure of fuel system such as importing spares for FOTP, Tank repair, Tank painting,
purchasing valves, purchasing of lube oil and so on (Total Cost is about £ 200,000 per year). I
also prepared cost estimations for above jobs, source of financing, procurement method, level of
authority, priority state, starting and ending date of jobs. Similarly, when I was working as
mechanical engineer for gas turbine, I followed same procedure for the jobs such as importing
spare parts for combustion inspection, Hot Gas Path Inspection and Major Inspection of GTs,
purchasing of generator bearings, Exhaust duct repair, Air filter house repair, spares for diesel
engine repair and so on (Total Cost is about £ 400,000 per year). This requires a sound
knowledge on financial handling and tuned up my knowledge a lot with on the job training.
During last five years in CEB, I handled many NCB and ICB tenders such as Refurbishment of
Hot Gas Path Components of G.E. Frame V Gas Turbines (Liners and Transition pieces),
Supply of labour for civil maintenance and general cleaning for KPS, obtaining services for
garbage disposal at KPS. By handling those tenders, I learnt how to prepare bid data sheet,
general tender conditions such as Scope of work, Bid and performance bond, price schedule
sheet, how to evaluate a tender, clearing and transport of materials, mode of payment, inspection
of material, shipment, insurance, proof of ability, warranty, arbitration and taxes and levies, etc.
6.1.4 Communication and Inter-personal skills
6.1.4.1 Communication skills developed during CEB career
I have maintained a good relationship with my superiors, colleagues and subordinates. Also, I am
participating for meetings with my higher management to discuss the progress, expenditures,
safety and all other issues in every special maintenance or project.
In every year, mechanical engineering students from many universities are coming to KPS for
industrial training for two or three months. They are trained in all the mechanical workshops and
maintenance activities under my supervision. Further, they are guided to understand the role of
38
the mechanical engineer in power generation. I was regularly entrusted to carry out public
awareness programs about energy efficiency through facilitation of plant visits for the general
public when I am working at KPS. Also, using my communication and leadership skills, I’ve
managed to convince the importance of energy conservation to general public.
6.1.4.2 Conducting Blood donation camp
Few years ago, a doctor from Maharagama Cancer hospital has informed me that lack of blood
during Sinhala New Year season in every year is affected cancer patient who are getting treatment
at hospital. Then, I discussed this matter with my boss to do the needful for solving this problem
since I was working as the Vice president of Kelanitissa Welfare society (KWS). After that I
discussed with our employees and decided to conduct blood donation camp in every year at KPS.
In this Sinhala New Year season, I was able to conduct 5th consecutive blood donation camp at
KPS. In every camp, there were more than ninety donors who helped for poor patients. As a vice
president of KWS, it was arranged to issue a certificate for all participant in every camp.
6.1.4.3 Six side cricket match in every year
To motivate employee at the office, a six-side cricket tournament is organized every year. All
employees of KPS are involved in this competition. There are many sponsors to provide foods,
certificates, gifts for the participants. With the help of staff, I have been successfully conducting
this tournament annually, since 2012.
6.1.5 Professional Conduct
6.1.5.1 Familiar with Relevant Legislation in Respect of Health, Safety & Risk
After posting me as a Mechanical Engineer (fuel system), I found that the employee awareness of
occupational safety, risk and health was not in satisfactory level and operation and maintenance
teams have not properly followed the guideline given in factory ordinance. I carried out a safety
audit and conducted safety training for operation and maintenance teams under the following
topics.

Identification of high risk activities such as hot work, work on or near electricity,
confined space entry, work at height, LOTO implementation and hoisting & rigging.

Risk assessment and accident prevention.

Handling of fire extinguishers.

Emergency preparedness and possible emergencies related to power plant.

Housekeeping & cleanliness.
39

General introduction of Factories Ordinance legal requirements.
Further all the required Personnel Protective Equipment (PPE) such as safety helmets, gloves,
muffs, and goggles were purchased and made available on power plant. Eight first aid boxes
were arranged within the power plant and instructions were given on how to maintain and
control them.
During the cement packing plant construction, I have arranged safety training for workers of
contactors, company staff and third party involved to project, with help of safety department.
According to company Occupational Health and Safety guidelines, I have analyzed possible risk
and hazards in my scope of work and established safety plane with help of safety officials
In August 2012, there was a strike of subordinates in CEB. They requested from our engineers’
unions also to join with them. But our unions saw the drawbacks of their strike to CEB and
people who are using electricity in the country, in case of power cut and decided not to support
them. So, engineers were only remaining for all the operations as well as maintenances in
Generation, Transmission and Distribution divisions in CEB. I engaged with both operation and
maintenance activities of the plant until situation is settled. Finally we were able to electrify
whole the country without any power cuts.
6.1.5.2 IESL –Mechanical Engineering Sectional Committee
I was one of representatives of Techno 2013 and 2014 on behalf of mechanical engineering
sectional committee. Also, I am an active member of United Professionals Movement (UPM)
for working against Indo-Sri Lanka Economic and Technology Cooperative Agreement (ETCA).
Also, I involved doing public awareness program on several occasions.
40
CHAPTER 07
7.1 CONTINUES PROFESSIONAL DEVELOPMENT ACTIVITIES FOR CAREER
DEVELOPMENT
No.
Course Attended
Conducted by
From
To
Duration
1
Master of Engineering in
Dept. of Mechanical Engineering,
2010
2013
04 Years
Manufacturing Systems
University of Moratuwa
21.12.2013
01.03.2014
12 Days
Engineering
2
3
Plumbing Engineering
The Institute of Engineers, Sri
(CPD)
Lanka (IESL)
Training on TG-50D5 Gas
Ethos Energy (Pvt) Ltd, Italy
19.10.2015
31.10.2015
14 Days
International Training
National Institute of solar Energy
10.11.2014
28.11.2014
21 Days
programme on Solar Energy
Gurgaon, India
13.09.2010
30.09.2010
09 Days
01.08.2011
18.08.2011
12 Days
07.03.2011
31.03.2011
14 Days
22.11.2011
23.12.2011
14 Days
14.11.2013
14.11.2013
1 Day
28.01.2015
29.01.2015
2 Days
11.02.2008
12.02.2008
02 Days
Turbine Operation &
Maintenance
4
Technologies & Applications
5
Level I Qualification of Non
Atomic Energy Authority, Sri
Destructive Testing in
Lanka
Magnetic Particle
6
Level II, Qualification of
Atomic Energy Authority, Sri
Non Destructive Testing in
Lanka
Magnetic Particle
7
Level I, Qualification of Non
Atomic Energy Authority, Sri
Destructive Testing in Eddy
Lanka
Current
8
9
10
11
Occupational Health &
Safety Unit of Ceylon Electricity
Safety
Board, Sri Lanka
Total Productive
National Productivity Secretariat,
Maintenance
Sri Lanka
Writing Work Place
Training Centre of Ceylon
Documents
Electricity Board, Sri Lanka
Communication Skills &
CEB Technical Training Centre
Interpersonal Relationship
41
12
for Executives
Piliyandala
Communication Skills
CEB Technical Training Centre
10.09.2007
11.09.2007
02 Days
Piliyandala
13
Practical Applications of 5S
Kerawalapitiya Power Plant
01.09.2015
01.09.2015
01 Day
14
Workshop on “Bid
Corporate Affair Branch, CEB
12.05.2015
13.05.2015
02 Days
Evaluation & Tendering
Procedures”
42
APPENDIX A: ORGANIZATION CHART OF KELANITISSA POWER STATION OF CEB
General
Manager
AFM
(Generation)
DGM
(Corporate
Affairs)
AGM
(Projects)
AGM (Proj.
& Anci.
Services)
Finance
Manager
AGM
(Transmissio
n)
AGM
(Generation)
AGM
(Distribution
Region 1)
AGM
(Distribution
Region 2)
AGM
(Distribution
Region 3)
AGM
(Distribution
Region 4
AGM
(Asset
Management
)
DGM
(Generation
Projects)
DGM
(Samanala
Complex)
DGM (Energy
Sales)
DGM
(Laxapana
Complex)
DGM
(Thermal
Complex)
DGM (Assest
Mgt Hydro
Electrical )
DGM (Assset
Mgt Thermal
Electrical)
DGM (Asserts
Mgt.
Mechanical Hydro)
DGM
(Asserts Mgt.
Mechanical Termal)
DGM (Civil
Maintenance
)
Chief Engineer
(SPS)
Chief Engineer
(KPS)
Chief Engineer
(UJPS)
Chief Engineer
(KCCPS)
Chief Engineer
(BPS)
Mechanical
Engineer (GT07)
Operations
Engineers ( 03 Nos)
Mechanical
superintendant
(M-2)
Electrical
superintendant (03
Nos)
Electrical Engineer
(EM)
Electrical Engineer
(I&C)
Mechanical
Enginner (GT)
Mechanical
Enginner (FS)
Electrical
superintendant
(M-1)
Electrical
superintendant
(M2)
Mechanical
superintendant
(M-1)
Mechanical
superintendantt
(M-1)
Fitter 04, & 06
helpers
Fitter 03, & 07
helpers
Civil
superintendant
(M-1)
Plumber/Carpento
r
Mason, Helpors
(25)
43
DGM
(Mahaweli
Complex)
APPENDIX B: ORGANIZATION CHART OF INTERNATIONAL PRECISION MOULDS AND TOOLS (PVT)
LTD.
Managing
Directors (01
No)
General
Manager
Engineering
Manager
(Design)
Design
Engineer (M1)
Design
Engineer (M2)
Design
Engineer (M3)
Engineering
Manager
(Production)
Design
Engineer (M4)
Production
Engineer
Production
Engineer
Production
Engineer
Machine
Operators (04)
Machine
Operators (04)
Machine
Operators (04)
44
Production
Trainee
Production
Trainee
APPENDIX C: ORGANIZATION CHART OF TRINITY PACKAGING (PVT)LTD.
Managing
Directors (01
No)
General
Manager
Maintenance
Engineer
Accountant
Assistant
Engineer
Supervisor
(02)
Mechanical/
Electrical
Fitters (03)
Machine
Operators
(15)
45
Helpers (10)