report training 2012

REPORT

ELECTRICAL SPECIALIST FOR HEALTH SAFETY

WORK TRAINING

By Sandy Bandung,16 – 28 April 2012

Training Subject on 1-st Week

Date Subject ReferenceStandard

Trainer

Mon,16 Apr ’12(08:00 – 17:00)

GENERATOR(Theory, Basic Operation, System Protection, Testing & safety inspection, maintenance )

• IEEE std C37.102-2005 Ir. Hasan Surya SE,MT(from Institute Technology Bandung (ITB))

Tue, 17 Apr ‘12(08:00 – 17:00)

PROTECTION SYSTEM(High Voltage (> 20 KV), medium voltage (415V – 20 KV), low voltage (415 V >)

• SNI 04-0225.3-2000 • IEEE std 242 – 2001• IEEE std 1015 - 2006

Ir. Yudi Prana Hikmat MT(from Institute Technology Bandung (ITB))

Wed,18 Apr ‘12(08:00 – 17:00)

• TRANSFORMATOR (Theory, Basic Operation, System Protection, Testing & safety inspection, Maintenance )

• LIGHTNING PROTECTION(Theory, Basic calculation for protection system )

• IEEE std C57.106-2002• IEEE std C37.91-2000• NFPA-780 2004• SNI IEC 62305-2 2008• IEEE Std 998-1996

Ir. Hasan Surya SE,MT(from Institute Technology Bandung (ITB))

Thu,19 Apr ‘12(08:00 – 17:00)

SYNCHRONOUS, INDUCTION & DC MOTOR(Theory, Basic Operation, System Protection, Testing & safety inspection, maintenance )

• IEEE Std C37.96-2000• IEEE Std 43 – 2000• IEEE Std 432-1992• SNI 04-0225.5-2000 •NFPA 70B

Ir. Yudi Prana Hikmat MT(from Institute Technology Bandung (ITB))

Fri, 20 Apr ‘12(08:00 – 17:00)

DESIGN DRAWING OF ELECTRICAL INSTALLATION(factory, building, hospital, Power house, Mining Industries)

• SNI 04-0225.4-2000• IEEE Std 315 – 1993

Ir. Robert A. Phillipus MT(from Institute Technology Bandung (ITB))

Sat, 21 Apr ‘12(08:00 – 17:00)

SPECIAL ELECTRICAL INSTALLATION FOR HAZARDOUS AREA(Theory , System Protection, Testing & safety inspection )

• SNI 04-0225.8-2000• IEC 60364-7 2008• NEC Article 500

DR. Ir. Toto Tohir MT(from Ministry of Labour and Transmigration representative)

Note : • IEEE : Institute of Electrical and Electronics Engineer • NFPA : National Fire Protection Association • IEC : International Electrotechnical Commission • NEC : National Electric Code• SNI : Standard National Indonesia

Training Subject on 2-nd Week

Date Subject ReferenceStandard

Trainer

Mon, 23 Apr ’12(08:00 – 17:00)

INDONESIAN REGULATION (General, Electrical & Lightning Safety Roles)

Indonesian Government Regulation :• UU No 1/1970• Kep -75/MEN/2002• Kep – 311/BW/2002• Per-02/MEN/1989• Per-05/MEN/1996

Ir. H. Ganjar Budiarto, Bc. Eng(from Ministry of Labour and Transmigration representative)

Tue, 24 Apr ‘12(08:00 – 17:00)

SWITCHGEAR (LVMDP & MVMDP)(Grounding system, Switchboard, Cable, Insulation tester, Earth Tester, Multi Tester, LBS, DS, CB, Arresters, etc)

• SNI 04-0225.7-2000 • IEC 60228• IEC 60269

DR. Ir. Toto Tohir MT(from Ministry of Labour and Transmigration representative)

Wed, 25 Apr ‘12(08:00 – 17:00)

• INSPECTION TEST(grounding system, insulation system, power generator)

• SAFETY AUDIT ELECTRICAL INSTALLATION at Polytechnic Institute Technology Bandung

• IEEE Std 515 – 1997• SNI 04-0225.9 - 2000

Ir. Yoseph M.Ir. Sutanto S.Ir. Robert A. Phillipus MT

Thu, 26 Apr ‘12(08:00 – 17:00)

DESIGN LIGHTING SYSTEM INSTALLATION(lux, lumen, RGB factor, Design interior, lighting intensity, etc)

• IEEE std 32 - 1972 Ir. Robert A. Phillipus MT(from Institute Technology Bandung (ITB))

Fri, 27 Apr ‘12(08:00 – 17:00)

FINAL TEST (Written test, Audit Presentation, Interview Test)

Ir. Robert A. Phillipus MTIr. Yudi Prana Hikmat MTDR. Ir. Toto Tohir MTIr. Hasan Surya SE,MT

EmployeeEmployee

Karawang Karawang regent officerregent officer

Karawang Karawang regent officerregent officer

Governor West of Java

Governor West of Java

Directorate General of labor Directorate General of labor development supervisorydevelopment supervisory

Ministry of labour and Ministry of labour and transmigration transmigration

Specialist HSWSpecialist HSWSpecialist HSWSpecialist HSW

Directors HSWDirectors HSW

Structure Organization

Indonesia HSW

ILTI ILTI ManagementManagement

ILTI ILTI ManagementManagement

Staff HSWStaff HSWStaff HSWStaff HSW

HSW : Health Safety Work (K3)

Karawang Karawang Safety OfficerSafety Officer

Karawang Karawang Safety OfficerSafety Officer

DoctorDoctorDoctorDoctor

Electrical specialist

SAFETY IN NUMBEROccupational accidents (19 per cent)

Main contributing and preventable factors: • lack of company/enterprise safety and health policy, structure, worker/employer collaborative mechanism, lack of occupational safety and health management system • poor safety culture • lack of knowledge, available solutions, awareness, information centres • lack of or poor government policies, lack of or poor legal enforcement and advisory system, lack of or poor tripartite cooperation • lack of incentive-based compensation system (experience rating) • lack of or poor occupational health services • lack of research and proper statistics for priority setting • lack of effective training and education system at all levels.

ELECTRICAL POTENTIAL HAZARD

1. Distortion Electrical Supply

1 Harmonic Distortion 5 Power Surges 9 Power Failure1 Harmonic Distortion 5 Power Surges 9 Power Failure

2 Switching Transients 6 Power Sags 2 Switching Transients 6 Power Sags

3 Line Noise3 Line Noise 7 High Voltage Spikes 7 High Voltage Spikes

4 Frequency Variations 8 Brownouts4 Frequency Variations 8 Brownouts

2. Direct Lightning Strike

Protect byProtect by

LIGHTNING CURRENTLIGHTNING CURRENT

ARESTER ARESTER

HARMONIC PROTECTIO N DEVICESHARMONIC PROTECTIO N DEVICES

This equipment already install on This equipment already install on FB05,06,07,08,09 & DCS systemFB05,06,07,08,09 & DCS system

RECOMMENDED TO INSTALL ON RECOMMENDED TO INSTALL ON ELECTRICAL PANEL SYSTEM ELECTRICAL PANEL SYSTEM

(MCC & SDP to protect Motor, DCS & (MCC & SDP to protect Motor, DCS & Filler machine)Filler machine)

3. Electrical Shock

UNINTERUPT UNINTERUPT

POWER SUPPLYPOWER SUPPLY

(UPS)(UPS) Protect byProtect by

This equipment already install on FB08,09 This equipment already install on FB08,09 Filler MC & DCS systemFiller MC & DCS system


This equipment NOT YET Install on ILTI Plant This equipment NOT YET Install on ILTI Plant it should be install on electronic devicesit should be install on electronic devices

This equipment NOT This equipment NOT RECOMMENDED by RECOMMENDED by

std IEEE, NFPA & SNIstd IEEE, NFPA & SNI




Ground systemGround system

INSULATION TRANSFORMERINSULATION TRANSFORMER

This equipment already install on This equipment already install on FB05,06,07,08, & 09FB05,06,07,08, & 09

Direct contactDirect contact Indirect contactIndirect contact

Earth Leak Circuit Breaker (ELCB)Earth Leak Circuit Breaker (ELCB)

This equipment NOT YET Install This equipment NOT YET Install on ILTI Planton ILTI Plant

1. All of ILTI Single line diagram should be revised follow international standard (IEC, IEEE 315: 1975, SNI 04-0225.

2. Switchboard office , MVMDP & Transformer should be maintenance for insulation cable test

: Drawing not standard

: It should be maintenance

ILTI sample drawing for single line diagram

: It should be install CB

ILTI Sample calculation (P-MCC7) for protection system

Std Ac tua l J udge Std Ac tua l J udge Std Ac tu a l J udge Std Ac tua l J udge Std Ac tua l J udge Std Ac tua l J udge Std Ac tua l J udge Std Ac tua l J udgeMo t o r Sp e c if ic a t io n1 Powe r P (kW) 1 1 1 1 1 1 1 1 1 1 7.5 7.5 1 12 Nomina l Cu rre n t In (A) 22.8 22.8 22.8 22.8 22.8 1 5.8 1 5.8 22.8

Sys t e m Pro t e c t io n1 Cable (1 ) s td ≤ Ac t (A) 28.5 35 OK 28.5 35 OK 28.5 35 OK 28.5 35 OK 28.5 35 OK 19.75 25 OK 19.75 25 OK 28.5 35 OK

s td ≤ Ac t (mm2) 4 6 OK 4 6 OK 4 6 OK 4 6 OK 4 6 OK 2.5 6 OK 2.5 6 OK 4 6 OK2 Ove rlo ad s e t s td ≥ Ac t (A) 23 19 OK 23 19 OK 23 19 OK 23 19 OK 23 19 OK 16 15 OK 16 15 OK 23 19 OK3 Co n ta c t o r s td ≤ Ac t (KW) 11 11 OK 11 11 OK 11 11 OK 11 11 OK 11 11 OK 7.5 11 OK 7.5 11 OK 11 11 OK4 MCCB (1) s td ≤ Ac t (A) 57 63 OK 57 63 OK 57 63 OK 57 63 OK 57 63 OK 39.5 50 OK 39.5 50 OK 57 OK

Std Ac tua l J udge Std Ac tua l J udge Std Ac tu a l J udge Std Ac tua l J udge Std Ac tua l J udge Std Ac tua l J udgeMo t o r Sp e c if ic a t io n1 Powe r P (kW) 7.5 7.5 7.5 6.6 6.6 6.62 Nomina l Cu rre n t In (A) 1 5.8 1 5.8 1 5.8 1 5.7 1 5.7 1 5.7

Sys t e m Pro t e c t io n1 Cable (1 ) s td ≤ Ac t (A) 19.75 25 OK 19.75 25 OK 19.75 25 OK 19.63 25 OK 19.63 25 OK 19.63 25 OK

s td ≤ Ac t (mm2) 2.5 6 OK 2.5 6 OK 2.5 6 OK 2.5 6 OK 2.5 6 OK 2.5 6 OK2 Ove rlo ad s e t s td ≥ Ac t (A) 16 15 OK 16 15 OK 16 15 OK 16 15 OK 16 15 OK 16 15 OK3 Co n ta c t o r s td ≤ Ac t (KW) 7.5 11 OK 7.5 11 OK 7.5 11 OK 6.6 11 OK 6.6 11 OK 6.6 11 OK4 MCCB (1) s td ≤ Ac t (A) 39.5 50 OK 39.5 50 OK 39.5 50 OK 39.25 50 OK 39.25 50 OK 39.25 50 OK

Note : 1. minimum design Cable for Sequirel Cage motor should be increase 125% from nominal Current (In) (PUIL 2000 : 5.5.3.1)2. minimum design CB for Sequirel Cage motor should be increase 250% from (nominal current (In) (PUIL 2000 : 5.5.5.23)

P- PT 067 P- PT 068

P- MT264 P- MT265 P- MT266 M- MT264 M- MT265 M- MT266

P- PT 061 P- PT 062 P- PT 063 P- PT 064 P- PT 065 P- PT 066Un itSTDEq u ipm e n t

Eq u ipm e n t STD Un it

1. Protection system for Switchboard MCC7 is already completed follow minimum standard requirement from IEC 60228 ,SNI 04-0225.5-2000, IEEE C37.96-2000

2. Need Calculation for others Switch board (MCC1 – 6, LP, PP, etc)

No Maintenance Activity Perform Characteristic Frequency Standard

1 Visual Inspection Minimum Inspection should look for: • Evidence of damage caused by dirt, loose parts, or foreign objects. • Verification that air inlets are not blocked • Evidence of moisture and/or dirt build-up • Unusual noises, leaking oil seals, or high v ibration • Oil level gages (if present) should be checked • Evidence of degradation of foundation, bed plates, anchor bolts • Evidence of oil rings turning (if applicable) • Evidence of leaking oil and piping and connections

6 month • NFPA 70B - 2006• IEEE std 43-2000

2 Oil analysis Sample and analyze.• Look at overall conditions and check for foreign matter, additive depletion, varnish precursors and metallic elements.


3 Running Current • Record and trend all three phase currents and verify the currents are balanced and do not exceed nameplate rating. • Each phase should be within +/- 5% of the average of all three phase


4 Insulation Resistance • Perform IR check between motor leads and ground. This determines condition of the ground insulation with acceptable reading > 5MΩ

24 month • NFPA 70B - 2006• IEEE std 43-2000• SNI 04.0225-2000

5 Polarization index (PI) • Ratio of the 10 minute IR to the 1 minute IR. (10 min IR / 1 min IR) • Determines condition of ground insulation • Test voltages similar to the IR test voltages Acceptance criteria ratio > 2


6 Winding resistance • A comparison of the line to line resistances of the motor’s winding. This test should be done at the motor terminals using a meter capable of measuring low resistance (milliohms). A typical ohm meter does not have adequate accuracy. Record, temperate correct and trend. Each phase should be within +/- (3% - 5%) of the average of all three phases


7 Stator visual Inspection Inspection should look for: • coil movement , plugged vent holes , soft or degraded insulation • coil bracing adequate and intact , lamination damage • partial discharge activity , tightness of wedges


8 Rotor visual Inspection Inspection should look for: • cracks in rotor bars , balance weights properly secured • signs of bar movement , signs of rotor/stator rub or lamination damage • cooling ducts clear , rubbing marks on shaft •keyway distortion


Motor Maintenance as NFPA & IEEE Std Recommendation

ILTI Grounding System

1. ILTI Grounding facility

Earth Resistance Test(Instrument)

3 point Method(NFPA 780)

No Maintenance Activity

Perform Characteristic Frequency

Standard

1 Visual Inspection Minimum Inspection should look for: (1) The system is in good repair.(2) There are no loose connections that might result in high-resistance joints.(3) No part of the system has been weakened by corrosion or vibration.(4) All down conductors and ground terminals are intact (non severed).(5) All conductors and system components are fastened securely to their mounting surfaces and are protected against accidental mechanical displacement as required.(6) There have not been additions or alterations to the protected structure that would require additional protection.(7) There is no visual indication of damage to surge suppression (overvoltage) devices.(8) The system complies in all respects with the current edition of thisstandard.

6 month

• NFPA 780 :2004• SNI IEC 62305-2 2008

2 Earth Resistance Test

•The instrument used in earth resistance testing should be capable of measuring 0 ohm to 5 ohms •The instrument used to measure bonding resistance should be capable of measuring 0 ohm to 1 ohm ± 10 percent.

12 month

• NFPA 780 :2004• SNI IEC 62305-2 2008

1. Need Instrument Earth Resistance Test to full fill Indonesia Safety Regulation no SNI IEC 62305-2 2008 or sub cont to 3-rd parties

2. Need Instrument Insulation Tester SNI 04-0225.3-2000 or sub cont to 3-rd parties

Insulation Tester

ILTI Lightning Protection System (LPS)

NFPA 780 as Standard for the Installation of Lightning Protection Systems 2004 Edition, determine the lightning risk assessment to provide the safeguarding of persons and property from hazards arising from exposure to lightning.

Based on data from BMG website, thunderstorm day (Value (number) of thunderstorms measured daily (Td/yr.)) defined as isoceraunic level (translated to Bhs. Indonesia as IKL) for Karawang region is considered high with value (Ng) = 0.1x 31 km2/years =3.1 km2/years . (see figure 1)

The yearly lightning strike frequency (Nd) to a structure is determined by the following equation:Nd = Ng . Ae . C1. 10-6

And the yearly lightning strike frequency for idemitsu plant are : 1.7 x 10-2

figure 1 :isoceraunic level

• The equivalent collective area of the structure (Ae) on ILTI plant could be determine by formula :

Ae : Π .9.H2 m2 With H = 20 m. Then Ae : 11,304 m2

• others factor we should be determine are environment coefficient (C1). Base on NFPA 780 table L.4.3 ILTI plant Structure located within a space containing structures or trees of the same height ortaller within a distance of 3H with index point : 0.5

•The yearly lightning strike frequency

Lightning Protection

To determine the tolerable of lightning frequency base on NFPA 780, we can be follow the formula below :Nc = 1.5 x 10-3 / C = 3 x 10-4

with C = C2.C3.C4.C5

•Tolerable lightning frequency & lightning protection level

• C2 : Determination of structural from metal Roof : 0.5• C3 : Standard value and non flammable : 1.0• C4 : Normal occupied : 1.0• C5 : Consequences to the environment : 10

1. ILTI plant should be install Lightning Protection System (LPS) with Class IV.

2. Type of Lightning Protection on ILTI plant is NOT RECOMENDED as STD IEEE 998:1996, NFPA 780 & SNI 62305-2:2008

Nd > Nc : Lightning Protection System should be install

1-Nc/Nd = 83% Class of Lightning Protection System (LPS) for ILTI plant : Level IV (Low level)

Type of lightning protection on ILTI Plant : Early Streamer Emission (ESM) lightning rods type (Active lightning Terminal)

1. Article 6 : Active lightning Terminal :It should be noted that IEEE does not recommend or endorse commercial offerings for early streamer emission system. (IEEE 998 : 1996)

2. Chapter 1 : Administration1.1.3 This document shall not cover lightning protection system installation requirements for early streamer emission systems or charge dissipation systems..(NFPA 780: 2004)


Lightning Protection•Traditional LPS Recommendation for ILTI


1. ILTI plant should be install Traditional Lightning Protection System (LPS) with Class IV as recommendation STD IEEE 998:1996, NFPA 780 & SNI 62305-2:2008

Conclusion

Review Drawing as Standard (One line diagram, Layout, Detail drawing, etc)Review HIRADC (Hazard Identification Risk Assessment Determine Control) documentation Review protection system on MCC panel, DCS system, Packaging machine, lightning protection & Office EquipmentGrounding, switchboard, MCC, lighting system inspectionReview Annual & Mid term preventive Maintenance ScheduleTraining Electrical potential hazard on workplace for all employee minimum 1 times/month Strong Recommended to add the Lightning Protection System (LPS) follow Indonesia (SNI) or International Standard (NFPA, IEEE)

Plan Activity for ILTI Plant :

Work Activity (Bandung, 16 – 27 April 2012)

1. Sharing information of electrical trouble shooting on each of company

2. Education, share knowledge, post Test & pre test

3. Test & analyze synchronous generator

4. Test & analyze Switchboard

5. Test & analyze Lightning protection

6. Test & Analyze Grounding system

7. Presentation safety audit

8. Final test (written test & interview)

RESULT FINAL TEST

No

Name Company Knowledge Skill Attitude Total Status

1 SANDY DAARIAAT, ST PT. IDEMITSU LUBE TECHNO INDONESIA

79.17 80 80 79.589 PASS

2 RONY AFANDI RAHMAN, ST PT. KALTIM PRIMA COAL (KPC)

72.33 66.5 80 72.115 PASS

3 HARMAWAN WITARNO, ST PT. KALTIM PARNA INDUSTRI (KPI)

72.5 80 80 76.25 PASS

4 ZULKIFLI, ST PT. TRANSPORTASI GAS INDONESIA (TGI)

73.5 77.5 80 76 PASS

5 LUTFI NUL HAKIM, ST PT. INDONESIA POWER 78 80 80 79 PASS

6 NOFRI NALDI, ST PT. PLN PJB II 76.92 78.5 80 78.01 PASS

Knowledge : 50%Skill : 30%Attitude : 20%

PASS : 65-80NOT PASS : <65

report training 2012

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