REPORT
ELECTRICAL SPECIALIST
FOR HEALTH SAFETY
WORK TRAINING
By Sandy
Bandung,16 – 28 April 2012
Training Subject on 1-st Week
Date Subject Reference
Standard
Trainer
Mon,16 Apr ’12
(08:00 – 17:00)
GENERATOR
(Theory, Ba...
Training Subject on 2-nd Week
Date Subject Reference
Standard
Trainer
Mon, 23 Apr ’12
(08:00 – 17:00)
INDONESIAN REGULATIO...
EmployeeEmployee
KarawangKarawang
regent officerregent officer
KarawangKarawang
regent officerregent officer
Governor
West...
SAFETY IN NUMBER
Occupational accidents (19 per cent)
Main contributing and preventable factors:
• lack of company/enterpr...
ELECTRICAL POTENTIAL HAZARD
1. Distortion Electrical Supply
1 Harmonic Distortion 5 Power Surges 9 Power Failure1 Harmonic...
1. All of ILTI Single line diagram should be revised follow
international standard (IEC, IEEE 315: 1975, SNI 04-0225.
2. S...
ILTI Sample calculation (P-MCC7) for
protection system
Std Ac tual J udge Std Ac tual J udge Std Ac tual J udge Std Ac tua...
No Maintenance Activity Perform Characteristic Frequency Standard
1 Visual Inspection Minimum Inspection should look for:
...
ILTI Grounding System
1. ILTI Grounding facility
Earth Resistance Test
(Instrument)
3 point Method
(NFPA 780)
No Maintenan...
ILTI Lightning Protection System (LPS)
NFPA 780 as Standard for the Installation of Lightning Protection Systems 2004 Edit...
Lightning Protection
To determine the tolerable of lightning frequency base on NFPA 780, we can be follow the formula belo...
Lightning Protection
•Traditional LPS Recommendation for ILTI
ILTI Lightning Protection System (LPS)
1. ILTI plant should ...
Conclusion
Review Drawing as Standard (One line diagram, Layout, Detail
drawing, etc)
Review HIRADC (Hazard Identification...
Work Activity (Bandung, 16 – 27 April 2012)
1. Sharing information of electrical
trouble shooting on each of company
2. Ed...
RESULT FINAL TEST
N
o
Name Company Knowledge Skill Attitude Total Status
1 SANDY DAARIAAT, ST PT. IDEMITSU LUBE
TECHNO IND...
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Report training 2012

  1. 1. REPORT ELECTRICAL SPECIALIST FOR HEALTH SAFETY WORK TRAINING By Sandy Bandung,16 – 28 April 2012
  2. 2. Training Subject on 1-st Week Date Subject Reference Standard 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
  3. 3. Training Subject on 2-nd Week Date Subject Reference Standard 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 MT Ir. Yudi Prana Hikmat MT DR. Ir. Toto Tohir MT Ir. Hasan Surya SE,MT
  4. 4. EmployeeEmployee KarawangKarawang regent officerregent officer KarawangKarawang regent officerregent officer Governor West of Java Governor West of Java Directorate General of laborDirectorate General of labor development supervisorydevelopment supervisory Ministry of labour andMinistry of labour and transmigrationtransmigration Specialist HSWSpecialist HSWSpecialist HSWSpecialist HSW Directors HSWDirectors HSW Structure Organization Indonesia HSW ILTIILTI ManagementManagement ILTIILTI ManagementManagement Staff HSWStaff HSWStaff HSWStaff HSW HSW : Health Safety Work (K3) KarawangKarawang Safety OfficerSafety Officer KarawangKarawang Safety OfficerSafety Officer DoctorDoctorDoctorDoctor Electrical specialist
  5. 5. SAFETY IN NUMBER Occupational 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.
  6. 6. 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 Sags2 Switching Transients 6 Power Sags 3 Line Noise3 Line Noise 7 High Voltage Spikes7 High Voltage Spikes 4 Frequency Variations 8 Brownouts4 Frequency Variations 8 Brownouts 2. Direct Lightning Strike Protect byProtect by LIGHTNING CURRENTLIGHTNING CURRENT ARESTERARESTER HARMONIC PROTECTIO N DEVICESHARMONIC PROTECTIO N DEVICES This equipment already install onThis equipment already install on FB05,06,07,08,09 & DCS systemFB05,06,07,08,09 & DCS system RECOMMENDED TO INSTALL ONRECOMMENDED TO INSTALL ON ELECTRICAL PANEL SYSTEMELECTRICAL PANEL SYSTEM (MCC & SDP to protect Motor, DCS &(MCC & SDP to protect Motor, DCS & Filler machine)Filler machine) 3. Electrical Shock UNINTERUPTUNINTERUPT POWER SUPPLYPOWER SUPPLY (UPS)(UPS) Protect byProtect by This equipment already install on FB08,09This equipment already install on FB08,09 Filler MC & DCS systemFiller MC & DCS system Protect byProtect by This equipment NOT YET Install on ILTI PlantThis equipment NOT YET Install on ILTI Plant it should be install on electronic devicesit should be install on electronic devices This equipment NOTThis equipment NOT RECOMMENDED byRECOMMENDED by std IEEE, NFPA & SNIstd IEEE, NFPA & SNI Protect byProtect by Protect byProtect by Protect byProtect by Ground systemGround system INSULATION TRANSFORMERINSULATION TRANSFORMER This equipment already install onThis 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 InstallThis equipment NOT YET Install on ILTI Planton ILTI Plant
  7. 7. 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
  8. 8. ILTI Sample calculation (P-MCC7) for protection system Std Ac tual J udge Std Ac tual J udge Std Ac tual J udge Std Ac tual J udge Std Ac tual J udge Std Ac tual J udge Std Ac tual J udge Std Ac tual J udge Mo t o r Spe c if ic a t io n 1 Powe r P (kW) 1 1 1 1 1 1 1 1 1 1 7.5 7.5 1 1 2 Nominal Curre nt 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 n 1 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 (mm 2 ) 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 OK 2 Ove rload 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 OK 3 Contac tor 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 OK 4 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 tual J udge Std Ac tual J udge Std Ac tual J udge Std Ac tual J udge Std Ac tual J udge Std Ac tual J udge Mo t o r Spe c if ic a t io n 1 Powe r P (kW) 7.5 7.5 7.5 6.6 6.6 6.6 2 Nominal Curre nt 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 n 1 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 (mm 2 ) 2.5 6 OK 2.5 6 OK 2.5 6 OK 2.5 6 OK 2.5 6 OK 2.5 6 OK 2 Ove rload 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 OK 3 Contac tor 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 OK 4 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 066 Un itSTDEqu ipm e n t Equ 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)
  9. 9. 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. 12 month • NFPA 70B - 2006 • IEEE std 43-2000 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 12 month • NFPA 70B - 2006 • IEEE std 43-2000 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 24 month • NFPA 70B - 2006 • IEEE std 43-2000 • SNI 04.0225-2000 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 24 month • NFPA 70B - 2006 • IEEE std 43-2000 • SNI 04.0225-2000 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 60 month • NFPA 70B - 2006 • IEEE std 43-2000 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 60 month • NFPA 70B - 2006 • IEEE std 43-2000 Motor Maintenance as NFPA & IEEE Std Recommendation
  10. 10. ILTI Grounding System 1. ILTI Grounding facility Earth Resistance Test (Instrument) 3 point Method (NFPA 780) No Maintenance Activity Perform Characteristic Freque ncy 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 this standard. 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
  11. 11. 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 or taller within a distance of 3H with index point : 0.5 •The yearly lightning strike frequency
  12. 12. 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 : Administration 1.1.3 This document shall not cover lightning protection system installation requirements for early streamer emission systems or charge dissipation systems..(NFPA 780: 2004) ILTI Lightning Protection System (LPS)
  13. 13. Lightning Protection •Traditional LPS Recommendation for ILTI ILTI Lightning Protection System (LPS) 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
  14. 14. 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 Equipment Grounding, switchboard, MCC, lighting system inspection Review Annual & Mid term preventive Maintenance Schedule Training 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 :
  15. 15. 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)
  16. 16. RESULT FINAL TEST N o 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 : 65-80 NOT PASS : <65

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