Ref Number: ACSB/SKO/W/SUM/1

SARAWAK OPERATIONS

WORKPACK

ACTIVITY : SWITCHGEAR & MCC MAINTENANCE

PLATFORM : TEMANA PLATFORM
EQUIPMENT : GS100, MCC-100, MCC-101
WO NUMBER :

SIGNATU
PERSONNEL NAME POSITION DATE
RE
Mohammad ACSB
PREPARED BY:
Yusmin ENGINEER
ACSB
REVIEWED BY: Azmi Ahmad
MANAGER
M Syakiq Mat PCSB
Sihat ENGINEER
ENDORSED BY:
PCSB
BME Manager
MANAGER
SECTION
APPROVED BY: HEAD
 SUMANDAK
OIM

TABLE OF CONTENTS

1 INTRODUCTION
2
1.1 Field Background
2
1.2 Project Background
2
1.3 Equipment Details & Specifications
3

2 DETAILED WORK SCOPE

4
2.1 Work Procedure 4
2.2 Work Planning
11

3 MANPOWER LOADING 14
3.1 Manpower List 14
3.2 Organization Chart
14
3.3 PCSB Focal Person
15
3.4 HSE Requirement
15
3.4.1 Toolbox Meeting 15
3.4.2 PTW 15
3.4.3 JHA 15

4 TOOLS & MATERIALS LIST

17
4.1 Tools & Parts Require
17
4.2 Lifting Plan
18

5 PROJECT DETAILS 21
5.1 Project Schedule
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:

5
2 DETAILED WORK SCOPE

2.1 Work Procedure

2.1.1ACB Panel Servicing & Testing

i. PTW and IEC Cert shall be approved by PCSB before work

commences.
ii. Switching (De-energize) to be done by PCSB Chargeman.
iii. Contractor to confirm no supply from ACB using HV Test
Pen.
iv. 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.
v. Compare nameplate data with drawings and specifications.
vi. Inspect circuit breaker for correct mounting.
vii. Operate circuit breaker to insure smooth operation.
viii. Inspect case for cracks or other defects.
ix. Inspect all bolted electrical connections for high resistance.
x. Inspect mechanism contacts and arc chutes in unsealed
units.
xi. Inspect anchorage, alignment, and grounding. Inspect
moving and stationary contacts for condition, wear, and
alignment.
xii. 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.
xiii. 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
 breaker insulation resistance should be in accordance with
attached appendices table for minimum IR value.
xiv. 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.
xv. Perform cleaning and lubricate the ACB contacts (aux,
finger) and linkages
xvi. Determine IR and contact resistant measurement after
servicing.
xvii. Check on earthing system, alignment and rack condition.
xviii. Report on abnormal findings immediately to PIC.
xix. Check for leftover tools and consumables.
xx. Rack in the breaker to service position.

2.1.3 MCC Servicing and Testing

i. PTW and IEC Cert shall be approved by PCSB before work

commences.
ii. Compare equipment nameplate data with drawings and
specifications.
iii. Inspect physical and mechanical condition.
iv. Inspect all bolted electrical connections for high resistance
v. Test all interlocking systems for correct operation and
sequencing.
vi. Inspect all indicating and control devices for correct
operation.
vii. Perform cleaning and servicing on contact, surface,
internal component and structural of MCC & proper
lubrication.
viii. Perform insulation-resistance tests on each pole, phase-to-
phase 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
ix. Report on abnormal findings immediately to PIC.
x. Check for leftover tools and consumables.

2.1.4 Busbar Servicing and Testing

i. PTW and IEC Cert shall be approved by PCSB before work

commences.
ii. Switching (De-energize) to be done by PCSB Chargeman.

7
 iii. Contractor to confirm no supply from busbar using HV Test
Pen.
iv. Before perform electrical test, ensure the entire load
(breaker, MCC, CT, VT and fuses) to busbar is
disconnected.
v. Compare equipment nameplate data with drawings and
specifications.
vi. Inspect busbar for physical damage and correct connection
in accordance with single-line diagram.
vii. Inspect all bolted electrical connections for high resistance.
viii. Verify tightness of accessible bolted electrical connections
by calibrated torque-wrench method
ix. Measure insulation resistance of each busbar, phase-to-
phase and phase-to-ground for one minute. Insulation-
resistance 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.
x. 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.
xi. Perform general cleaning on busbar
xii. Apply all new silicon sealant to all busduct joint and
gasket.
xiii. Measure IR and contact resistance after service.
xiv. Report on abnormal findings immediately to PIC.
xv. Check for leftover tools and consumables.
xvi. 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
 current through switches and over current protective
devices.
ii. 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.
iii. The surface of the conductor is free from carbon and other
foreign matter that can become conductive on humid
conditions.
iv. Applied voltage is not too high when testing low voltage
system. Too much voltage will damage the insulation.
v. 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. Never connect the insulation tester to energized

conductors or energize equipment and always follow
manufacturer’s recommendation.
ii. Shut down the equipment to be tested by opening fuses,
switches and circuit breakers.
iii. Disconnect the branch circuit conductor, grounding
conductor and all other equipment from the unit under
test.
iv. Discharge conductor capacitance, both before and after
the test. Some instrument may have automatic discharge
functions.

v. Check for any leakage current through fuses, switches and

breakers on de- energized circuits. Leakage current can
cause inconsistent and incorrect reading.
vi. Do not use an insulation tester in dangerous or explosive
atmosphere since the instrument can generate arching in
damaged insulation.
vii. Use insulated rubber glove when connecting the test lead.

Procedure of Insulation Resistance Test

i. Use multimeter or voltmeter to make sure there is no

power applied to the tested circuit.
ii. 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. 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.
iv. 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.
v. 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.
vi. Test the insulation between phase to phase and phase to
neutral as per checklist.
vii. Keep a dated record of the measured value.
viii. 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

10
 Figure 2: Connection Diagram of Busbar Insulation Resistance Test

B. Micro-ohm Measurement/Contact Resistance/Ductor Test

Procedure Performing Contact Resistance Test

i. Make certain that the circuit breaker is de-energised on both sides, closed
and safety grounded and that local safety regulations are followed.
ii. Ground the test instrument.
iii. Make sure that the test instrument is switched off.
iv. Connect current and sensing cables according to the drawing.
v. Switch the test instrument on.
vi. Set the test current to minimum 100A (according to ANSI C 37.09)
vii. Perform the measurement.
viii. Repeat the test on the different phase.

11
 Figure 3: Connection Diagram of Ductor/Contact Resistance Test

2.2 Work Planning

2.2.1 Shutdown activity

Day Work Description Plan
Man
Hours
1 - Arrival at Temana Platform 12 hrs
- 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

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 GS-100 busbar

ET : 4
hrs
ACB 1. ACB G700 Gas Generator
ET : 3 2. ACB G710 Diesel Generator
hrs 3. ACB Bustie

- Housekeeping and apply PTW for next day activities and

submit report to PIC.
ET : 1 hr
2 - Arrival at Temana Platform 12 hrs
- 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
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 Busbar MCC100

ET : 4
hrs

13
 MCC 15 units MCC
ET : 4 2 units Isolator Switch
hrs

- Housekeeping and apply PTW for next day activities and

submit report to PIC.
ET : 1 hr
3 - Arrival at Temana Platform 12 hrs
- 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
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 15 units MCC
ET : 4 2 units Isolator Switch
hrs

- Housekeeping and apply PTW for next day activities and

submit report to PIC.
ET : 1hr
4 - 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 SB-
7720.
ET : 8 hr

- Housekeeping and apply PTW for next day activities and

submit report to PIC.
ET : 1hr

3 MANPOWER LOADING

3.1 Manpower List

Below is the list of manpower for site work activities:

N Name Designati IC No. HUET Medical

o. on Expiry Expiry
Date Date
1 Engineer 8110060351 09/03/201 01/01/201
Mohammad Yusmin 83 4 2
2
3 Technician 8512314956 26/01/201 17/01/201
Dianto Rasali 17 4 2
4 Muhd Daud Abd Technician 8608042953 17/08/201 05/09/201
Wahab 27 3 1
5 Technician 8011231152 28/06/201 29/06/201
Roslan Abu Bakar 71 2 2
6 Mohd Sabri Abdul Technician 8112181154 16/05/201 21/05/201
Ghani 41 2 2

15
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
syaqiq_matsihat@petronas.com.my

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

17
4 TOOLS & MATERIAL LIST

4.1 Tools & Parts Required

No Description Quantity
1 IR Tester 1kV 3
2 Contact Resistance Tester 1
3 Digital Multimeter 2
4 Test plug 1
5 Digital clamp meter 2
6 Discharge Rod 1
7 Blower 1
8 Vacuum Cleaner 1
9 Common Tools (Tools bag) 2
10 Long nose pliers 8 inch 2
11 Locking pliers 8 inch 2
12 Adjustable spanner 8 inch 4
13 Adjustable spanner 12 inch 2
14 Iron saw with blade 2
15 Iron saw with blade small 2
16 Flat file (Kikir) 2
17 Round file (Kikir) 2
18 Steal brush 2
19 Cable snapper 2
20 Common Spanners set 2
21 Power Extension Cords 2
22 Torchlight (explosion proof) 1
23 Torque Wrench (8-60 Nm) 1
24 Cordless Drill (12 Volt) 1
25 Paint brush 1
26 Digital camera 1
27 WD-40 4
28 Contact Cleaner 4
29 3M Tape 4
30 Cotton Rag 1 pack
31 Sand Paper 4
32 Teflon Tape 1 pack
33 Cotton Hand Glove 1 pack
34 Masking Tape 4
35 Plastic Bag 1 pack
36 PVC Tape (Red, yellow, blue, black & green) 6 each
37 Cable/busbar cleaner 4
38 Barricade tape 2

18
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

19
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

21
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

23