Ref Number: ACSB/SKO/W/SUM/1
SARAWAK OPERATIONS
WORKPACK ACTIVITY : PLATFORM EQUIPMENT : WO NU NUMBER :
SWITCHGEAR & MCC MAINTENANCE TEMANA PLATFORM : GS100, MCC-100, MCC-101
PERSONNEL
NAME
POSITION
PREPARED BY:
Mohammad Yusmin
REVIEWED BY:
Azmi Ahmad
ACSB ENGINEER ACSB MANAGER PCSB ENGINEER PCSB MANAGER SECTION HEAD
ENDORSED BY:
M Syakiq Mat Sihat BME Manager
APPROVED BY:
SIGNATU RE
DATE
SUMANDAK OIM
TABLE OF CONTENTS
1
INTRODUCTION 2 1.1 2 1.2 2 1.3 3
2
4
Equipment Details & Specifications
Work Procedure Work Planning
MANPOWER LOADING 3.1 Manpower List 3.2 Organization Chart 14 3.3 PCSB Focal Person 15 3.4 HSE Requirement 15 3.4.1 Toolbox Meeting 3.4.2 PTW 3.4.3 JHA
4
14 14
15 15 15
TOOLS & MATERIALS LIST 17 4.1 17 4.2 18
5
Project Background
DETAILED WORK SCOPE 4 2.1 2.2 11
3
Field Background
Tools & Parts Require Lifting Plan
PROJECT DETAILS 5.1 Project Schedule 21
21
2
6
APPENDICES 21
3
1 INTRODUCTION 1.1 Field Background Temana Platform 1.2 Project Background This shutdown maintenance and services of the switchgear and MCC at Temana platform is to maintain the equipment as per routine activity as per below: a) Shall perform visual inspection for damage, overheating, corrosion, cracked insulation and loose terminals. b) Shall perform general cleaning on switchgear (ACB, MCC, busbar, compartment, etc). c) Shall perform insulation resistance for contactor and circuit breaker. d) Shall perform continuity check by measuring closed contact resistance of contactor. e) Shall verify conductivity, continuity and integrity of the busbar assembly, switchgear earthing and bonding. f) Shall perform functional check on switchgears and MCC inclusive of control systems and electrical/mechanical interlocks. g) Shall verify the ACB and MCC panels operation and interlocks. h) Shall verify the control wiring system against the schematic diagram. i) Shall inspect and service MCC contactors and circuit breakers for condition, alignment and correct setting. j) Shall troubleshoot and rectify any switchgear and MCC having abnormalities. k) Shall perform testing and recording data. l) Shall perform tightening for any losing part. m) Shall perform cleaning
4
1.3 Equipment Details & Specifications Lists below show the switchgears and MCC involved during shutdown maintenance:
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2 DETAILED WORK SCOPE 2.1
Work Procedure
2.1.1ACB Panel Servicing & Testing i. ii. iii. iv.
v. vi. vii. viii. ix. x. xi. xii.
xiii.
PTW and IEC Cert shall be approved by PCSB before work commences. Switching (De-energize) to be done by PCSB Chargeman. Contractor to confirm no supply from ACB using HV Test Pen. Switchgear Panel to be placed at the Earth Position. Before inspecting or performing any maintenance on either the breaker or its mechanism, be sure the breaker is in the open position. Both the closing and opening, springs should be discharged or blocked mechanically before any maintenance is done. Compare nameplate data with drawings and specifications. Inspect circuit breaker for correct mounting. Operate circuit breaker to insure smooth operation. Inspect case for cracks or other defects. Inspect all bolted electrical connections for high resistance. Inspect mechanism contacts and arc chutes in unsealed units. Inspect anchorage, alignment, and grounding. Inspect moving and stationary contacts for condition, wear, and alignment. Perform a contact-resistance test. Microhm drop values shall not exceed the high levels of the normal range as indicated in the manufacturer’s published data. If manufacturer’s data is not available, investigate any values which deviate from similar connections by more than 50 percent of the lowest value. Perform an insulation-resistance test at 1000 volts dc from pole-to-pole and from each pole-to-ground with breaker closed and across open contacts of each phase. Circuit 6
xiv. xv. xvi. xvii. xviii. xix. xx.
breaker insulation resistance should be in accordance with attached appendices table for minimum IR value. Clean the area of arc chutes until thoroughly clean and ensure the arc chutes are clear of contamination and have no significant damage on grids or ceramics. Perform cleaning and lubricate the ACB contacts (aux, finger) and linkages Determine IR and contact resistant measurement after servicing. Check on earthing system, alignment and rack condition. Report on abnormal findings immediately to PIC. Check for leftover tools and consumables. Rack in the breaker to service position.
2.1.3 MCC Servicing and Testing i. ii. iii. iv. v. vi. vii. viii.
ix. x.
PTW and IEC Cert shall be approved by PCSB before work commences. Compare equipment nameplate data with drawings and specifications. Inspect physical and mechanical condition. Inspect all bolted electrical connections for high resistance Test all interlocking systems for correct operation and sequencing. Inspect all indicating and control devices for correct operation. Perform cleaning and servicing on contact, surface, internal component and structural of MCC & proper lubrication. Perform insulation-resistance tests on each pole, phase-tophase and phase-to-ground with switch closed and across each open pole for one minute. Test voltage and minimum insulation resistance shall be in accordance with manufacturer’s published data or attached table on appendices Report on abnormal findings immediately to PIC. Check for leftover tools and consumables.
2.1.4 Busbar Servicing and Testing i. ii.
PTW and IEC Cert shall be approved by PCSB before work commences. Switching (De-energize) to be done by PCSB Chargeman. 7
iii. iv. v. vi. vii. viii. ix.
x.
xi. xii. xiii. xiv. xv. xvi.
Contractor to confirm no supply from busbar using HV Test Pen. Before perform electrical test, ensure the entire load (breaker, MCC, CT, VT and fuses) to busbar is disconnected. Compare equipment nameplate data with drawings and specifications. Inspect busbar for physical damage and correct connection in accordance with single-line diagram. Inspect all bolted electrical connections for high resistance. Verify tightness of accessible bolted electrical connections by calibrated torque-wrench method Measure insulation resistance of each busbar, phase-tophase and phase-to-ground for one minute. Insulationresistance test voltages and resistance values shall be in accordance with manufacturer’s published data or attached table on appendices. Minimum resistance values are for a nominal 1000 foot busbar run. Perform contact-resistance test on each connection point of non-insulated busbar. Compare bolted connection resistances and bus joint resistances to values of similar connections. Microhm drop values shall not exceed the high levels of the normal range as indicated in the manufacturer’s published data. If manufacturer’s data is not available, investigate any values which deviate from similar connections by more than 50 percent of the lowest value. Perform general cleaning on busbar Apply all new silicon sealant to all busduct joint and gasket. Measure IR and contact resistance after service. Report on abnormal findings immediately to PIC. Check for leftover tools and consumables. Closed the busbar compartment.
2.1.5 Testing Procedure A. Insulation Resistance Test Procedure before Performing Insulation Resistance Test i.
The system or equipment is taken out of service and disconnected from all other circuits, switches, capacitors, brushes, lightning arrestors and circuit breakers. (Make sure the measurements are not affected by leakage 8
ii.
iii. iv. v.
current through switches and over current protective devices. The temperature of the conductor is above the dew point of the ambient air. When this is not the case, a moisture coating will form on the insulation surface and in some cases will be absorbed by the material. The surface of the conductor is free from carbon and other foreign matter that can become conductive on humid conditions. Applied voltage is not too high when testing low voltage system. Too much voltage will damage the insulation. The system under test needs completely discharged to the ground. The grounding discharge time should be about five times the testing charge time.
Safety Procedure on Insulation Resistance Test i. ii. iii. iv.
v. vi. vii.
Never connect the insulation tester to energized conductors or energize equipment and always follow manufacturer’s recommendation. Shut down the equipment to be tested by opening fuses, switches and circuit breakers. Disconnect the branch circuit conductor, grounding conductor and all other equipment from the unit under test. Discharge conductor capacitance, both before and after the test. Some instrument may have automatic discharge functions. Check for any leakage current through fuses, switches and breakers on de- energized circuits. Leakage current can cause inconsistent and incorrect reading. Do not use an insulation tester in dangerous or explosive atmosphere since the instrument can generate arching in damaged insulation. Use insulated rubber glove when connecting the test lead.
Procedure of Insulation Resistance Test i. ii.
Use multimeter or voltmeter to make sure there is no power applied to the tested circuit. Set the voltage level to as per table attached on appendices depend on equipment. E.g. 1000V for LV switchboard (ACB, MCC) and 2500V for MV switchboard (VCB). 9
iii.
iv. v.
vi. vii. viii.
Plug one end of the black test lead to the common terminal on the meter end and touch the test probe to the ground or another conductor. Sometimes it is helpful to ground all conductors that are not part of the test. Plug one end of the red test lead to the volt/ohm terminal on the meter and connect the test probe to the conductor to be tested. Press the test button to apply the desired voltage and read the resistance display on the meter. It could take a few seconds for the reading to be settled. The higher the resistance the better. Test the insulation between phase to phase and phase to neutral as per checklist. Keep a dated record of the measured value. If some of the conductors fail the test, identify the problems and take necessary actions. Moisture, water and dirt can create low resistance readings.
Figure 1: Connection Diagram of CB Insulation Resistance Test
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Figure 2: Connection Diagram of Busbar Insulation Resistance Test
B. Micro-ohm Measurement/Contact Resistance/Ductor Test Procedure Performing Contact Resistance Test i. ii.
iii. iv. v. vi. vii. viii.
Make certain that the circuit breaker is de-energised on both sides, closed and safety grounded and that local safety regulations are followed. Ground the test instrument. Make sure that the test instrument is switched off. Connect current and sensing cables according to the drawing. Switch the test instrument on. Set the test current to minimum 100A (according to ANSI C 37.09) Perform the measurement. Repeat the test on the different phase.
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Figure 3: Connection Diagram of Ductor/Contact Resistance Test
2.2 Work Planning
2.2.1 Day
1
Shutdown activity Work Description
-
Arrival at Temana Platform Apply for PTW, ensure isolation certificate in place, and prepare the worksite. ET : 2 hrs
-
Do a toolbox meeting prior to the job. Barricade the work area to prevent unauthorized personnel enter the area. Ensure system is disconnected from all electrical sources and do a proof test to ensure system is totally
-
Plan Man Hours 12 hrs
12
dead. ET : 1 hr -
Shutdown activities: To perform servicing on busbar and dropper on switchgear GS-100 as per work scope and listed as per table below: Busbar ET : 4 hrs ACB ET : 3 hrs
2
-
-
-
GS-100 busbar
1. ACB G700 Gas Generator 2. ACB G710 Diesel Generator 3. ACB Bustie
Housekeeping and apply PTW for next day activities and submit report to PIC. ET : 1 hr Arrival at Temana Platform Apply for PTW, ensure isolation certificate in place, and prepare the worksite. ET : 2 hrs
12 hrs
Do a toolbox meeting prior to the job. Barricade the work area to prevent unauthorized personnel enter the area. Ensure system is disconnected from all electrical sources and do a proof test to ensure system is totally dead. ET : 1 hr Shutdown activities: To perform servicing on busbar and MCC at switchgear MCC100 as per work scope and listed as per table below: Busbar ET : 4 hrs
Busbar MCC100
13
MCC ET : 4 hrs
3
-
-
15 units MCC 2 units Isolator Switch
Housekeeping and apply PTW for next day activities and submit report to PIC. ET : 1 hr Arrival at Temana Platform Apply for PTW, ensure isolation certificate in place, and prepare the worksite. ET : 2 hrs
12 hrs
Do a toolbox meeting prior to the job. Barricade the work area to prevent unauthorized personnel enter the area. Ensure system is disconnected from all electrical sources and do a proof test to ensure system is totally dead. ET : 1 hr Shutdown activities: To perform servicing on busbar and MCC at switchgear MCC101 as per work scope and listed as per table below: Busbar Busbar MCC100 ET : 4 hrs MCC ET : 4 hrs
4
-
15 units MCC 2 units Isolator Switch
Housekeeping and apply PTW for next day activities and submit report to PIC. ET : 1hr Ensure PTW and isolation certificate in place, and prepare the worksite. ET : 1 hr
-
Do a toolbox meeting prior to the job. Barricade the work area to prevent unauthorized personnel enter the area. ET : 1 hr
-
Post-Shutdown activities: To perform servicing on remaining VCB, VCU, ACB and MCC and also perform 14
thermography on switchgear SG-7510. SB7710 and SB7720. ET : 8 hr -
3
Housekeeping and apply PTW for next day activities and submit report to PIC. ET : 1hr
MANPOWER LOADING
3.1 Manpower List Below is the list of manpower for site work activities: N o.
Name
1
Designati on
IC No.
Engineer Mohammad Yusmin
2 3 4
Technician Dianto Rasali Muhd Daud Abd Wahab
5 6
Technician Technician
Roslan Abu Bakar Mohd Sabri Abdul Ghani
Technician
8110060351 83
HUET Expiry Date 09/03/201 4
Medical Expiry Date 01/01/201 2
8512314956 17 8608042953 27 8011231152 71 8112181154 41
26/01/201 4 17/08/201 3 28/06/201 2 16/05/201 2
17/01/201 2 05/09/201 1 29/06/201 2 21/05/201 2
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3.2 Organization Chart
3.3 PCSB Focal Person Muhammad Syaqiq Bin Mat Sihat, Maintenance Department (BME-5), PCSB-Sarawak Operation Tel : 085-475874 Mobile : 013-7112301
[email protected] 3.4 HSE Requirement 3.4.1 Toolbox Meeting • •
• •
Work leader will briefly discuss the work plan. Possible injuries from Electricity such as Dangers from electricity: Voltage can cause ventricular fibrillation (stop heart function). Current flow can cause severe burns. 16
Reaction to Electric Shock (varies and can depend on) Voltage level and duration Physical condition of victim Contact area with voltage Victim skin condition Ambient conditions Before carrying out the switching work, several safety precautions has to be observed such as, Isolation / switching must be performed by competent / authorized person. Ensure the breaker/MCC is dead before carrying out any maintenance. Care should be taken when withdrawing and removing breaker/MCC carriage. Breaker/MCC servicing should be performed by a team of at least 2 persons.
• • • • • •
3.4.2
Permit to Work •
The objective of electrical work permits is to establish safe working practices by Defines responsibilities Specifies the work & time period the permit is valid Precautions to be taken for the work Defines safe working limits to avoid DANGER Defines procedures to be followed Identifies any special equipment, tools or clothing A few people of ASAGA personnel who involved with this turnaround maintenance attend PETRONAS Carigali PTW Applicant course.
•
3.4.3 Job Hazards Analysis See Attachment on appendices for JHA
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4 TOOLS & MATERIAL LIST 4.1 Tools & Parts Required No Description 1 IR Tester 1kV 2 Contact Resistance Tester 3 Digital Multimeter 4 Test plug 5 Digital clamp meter 6 Discharge Rod 7 Blower 8 Vacuum Cleaner 9 Common Tools (Tools bag) 10 Long nose pliers 8 inch 11 Locking pliers 8 inch 12 Adjustable spanner 8 inch 13 Adjustable spanner 12 inch 14 Iron saw with blade 15 Iron saw with blade small 16 Flat file (Kikir) 17 Round file (Kikir) 18 Steal brush 19 Cable snapper 20 Common Spanners set 21 Power Extension Cords 22 Torchlight (explosion proof) 23 Torque Wrench (8-60 Nm) 24 Cordless Drill (12 Volt) 25 Paint brush 26 Digital camera 27 WD-40 28 Contact Cleaner 29 3M Tape 30 Cotton Rag 31 Sand Paper 32 Teflon Tape 33 Cotton Hand Glove 34 Masking Tape 35 Plastic Bag 36 PVC Tape (Red, yellow, blue, black & green) 37 Cable/busbar cleaner 38 Barricade tape
Quantity 3 1 2 1 2 1 1 1 2 2 2 4 2 2 2 2 2 2 2 2 2 1 1 1 1 1 4 4 4 1 pack 4 1 pack 1 pack 4 1 pack 6 each 4 2
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4.2 Lifting Plan During the turnaround activity, ASAGA team will bring a numbers of boxes and need a crane service to carry the loads to the platform. The dimension and estimated weight of the boxes as illustrated below. ITEM 1 BOX 1: Tools and Test Equipments
Dimension : 24” x 54” x 22” Estimated weight : 50kg ITEM 2 BOX 2: Tools and Test Equipments
Dimension : 27” x 55.5” x 18” Estimated weight : 50kg
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ITEM 3 BOX 3: Tools and Test Equipments
Dimension : 17” x 21” x 15” Estimated weight : 25kg ITEM 4 BOX 4: Contact Resistance Tester
Dimension : 19” x 22” x 10” Estimated weight : 20kg
20
ITEM 5 BOX 5: Plastic Container
Dimension : 19” x 22” x 10” Estimated weight : 20kg ITEM 6
2x Fiber Ladder
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5 PROJECT DETAILS 5.1 Project Schedule
22
6 APPENDICES 6.1 Job Hazard Analysis 6.2 Single Line Drawing 6.3 QA/QC Plan - Checklist
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