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A dilbo-EE performing NS in Bintulu logs work and after-work activity for project-record purposes and posterity.
Sunday, August 10, 2003
There's this mysterious rotten egg smell that comes out of my lungs when I breath at night. Could my lungs be saturated with H2S? A DOSH page online says an H2S safety limit is 5ppm. Am going to get a Crowcon Tetra H2S & LEL meter for about RM8000 using the staff bonus this year. As the saying goes, "safety first". E-mailed boss to ask if the H2S meter is claimable, but no reply yet.
Now I know why practically all the "kasta rendah" workers hock green phlegm & long term site staff have developed strange coughs & speech impediments. But it may be too early to speculate. Get the meter first & measure H2S at normal working areas. The results will be of most interest..
This bothersome H2S smell goes after spending a long time onsite, but returns when I go to swim. Could it mean my sense of smell gets knocked out after a while onsite? If so, this could be why so many site staff smoke --- to lose their sense of smell so that the H2S odor doesn't keep them awake at night or give them headaches. The cigarette smoke is taken to as a sort of inoculant. Interesting theory, but am going to have to put up with this rotten egg smell for the next 2-3years of NS..
Now I know why practically all the "kasta rendah" workers hock green phlegm & long term site staff have developed strange coughs & speech impediments. But it may be too early to speculate. Get the meter first & measure H2S at normal working areas. The results will be of most interest..
This bothersome H2S smell goes after spending a long time onsite, but returns when I go to swim. Could it mean my sense of smell gets knocked out after a while onsite? If so, this could be why so many site staff smoke --- to lose their sense of smell so that the H2S odor doesn't keep them awake at night or give them headaches. The cigarette smoke is taken to as a sort of inoculant. Interesting theory, but am going to have to put up with this rotten egg smell for the next 2-3years of NS..
Cut off Date: 8 Aug 2003
Activities achieved for the week
1) Module 5 revamp electrical briefing by Supervisor
2) Commencement of lighting reinstallation at fin fan area
Cut off Date: 1 Aug 2003
Activities achieved for the week
1) 1st & 2nd coats of paint for electrochlorination piping.
2) Electrolization cell D piping butterfly valve replacement due to leak.
3) 4201D deenergisation & reenergisation for CELL D waterflush & acidclean.
4) Erection of scaffolding for cabletray replacement at Terminal water intake area.
5) Removal of old UPS rectifiers from New/Renovated Terminal Building.
6) Installation of new UPS at Main Office Building
Activities achieved for the week
1) Module 5 revamp electrical briefing by Supervisor
2) Commencement of lighting reinstallation at fin fan area
Cut off Date: 1 Aug 2003
Activities achieved for the week
1) 1st & 2nd coats of paint for electrochlorination piping.
2) Electrolization cell D piping butterfly valve replacement due to leak.
3) 4201D deenergisation & reenergisation for CELL D waterflush & acidclean.
4) Erection of scaffolding for cabletray replacement at Terminal water intake area.
5) Removal of old UPS rectifiers from New/Renovated Terminal Building.
6) Installation of new UPS at Main Office Building
Sunday, July 27, 2003
Activities achieved for the week ending 29 Jul 2003
1) Transformer 4201C deenergisation, dielectric tests for old, new & new-postfiltered oil.
2) Installation of Swagelok Fitting and purge spool for N2 inerting after oil-filling.
3) 4201C Gate Pulse Array replacement per contract.
4) Pumpout old oil and fill-up 4201C.
5) Seawater flow startup & energisation of 4201C for overnight no-load test.
6) Deenergisation of 4201C, oil dielectric retest, reenergisation for 75% overnight load test.
7) Relocate scaffolding from 4201C to 4201D
8) Transformer 4201D deenergisation, dielectric tests for old, new & new-postfiltered oil.
9) Installation of Swagelok Fitting and purge spool for N2 inerting after oil-filling.
10) 4201D busbar retorquing and chassis paint touch-up.
11) 4201D Gate Pulse Array replacement per contract.
12) Seawater flow startup & energisation of 4201D for overnight no-load test.
13) Deenergisation of 4201D, oil dielectric retest, reenergisation for 75% overnight load test.
14) 4201A-D electrode scaffolding removal by busbar clamp installation contractor
15) 4201 A-D electrode scaffolding reinstallation by painting contractor
16) Replacement of damaged Exe phone cable in Electrochlorination Plant
17) Replcament of faulty/aged lighting in Electrochlorination Plant
18) Demobilisation of Transformer Oil Change Vendor
19) Attend Clearance Certificate/Permit to Work briefing by HSE and sit for Work Supervisor Test
1) Transformer 4201C deenergisation, dielectric tests for old, new & new-postfiltered oil.
2) Installation of Swagelok Fitting and purge spool for N2 inerting after oil-filling.
3) 4201C Gate Pulse Array replacement per contract.
4) Pumpout old oil and fill-up 4201C.
5) Seawater flow startup & energisation of 4201C for overnight no-load test.
6) Deenergisation of 4201C, oil dielectric retest, reenergisation for 75% overnight load test.
7) Relocate scaffolding from 4201C to 4201D
8) Transformer 4201D deenergisation, dielectric tests for old, new & new-postfiltered oil.
9) Installation of Swagelok Fitting and purge spool for N2 inerting after oil-filling.
10) 4201D busbar retorquing and chassis paint touch-up.
11) 4201D Gate Pulse Array replacement per contract.
12) Seawater flow startup & energisation of 4201D for overnight no-load test.
13) Deenergisation of 4201D, oil dielectric retest, reenergisation for 75% overnight load test.
14) 4201A-D electrode scaffolding removal by busbar clamp installation contractor
15) 4201 A-D electrode scaffolding reinstallation by painting contractor
16) Replacement of damaged Exe phone cable in Electrochlorination Plant
17) Replcament of faulty/aged lighting in Electrochlorination Plant
18) Demobilisation of Transformer Oil Change Vendor
19) Attend Clearance Certificate/Permit to Work briefing by HSE and sit for Work Supervisor Test
Thursday, July 24, 2003
Activities achieved for the week ending Jul22
1) Post overnight noload test oil sampling and dielectric test for electrochlorination transformer 4201A.
2) Overnight loaded test of transformer 4201A; tempaerature check.
3) Deenergisation of transformer 4201B.
4) Filter new oil for transformer 4201B.
5) Replace fuse & thyristor for transformer 4201A after tripping on second night of loaded operation.
6) Install new Gate Pulse Array circuit board for transformer 4201B.
7) Oil sampling and dielectric testing ofr 4201B old, new unfiltered and new filtered oil.
8) Pumpout old oil and fill-up 4201B. Post-fill oil sampling and dielectric test.
9) Re-energise 4201A and energise 4201B for no-load test.
10) Deenergise and reenergise 4201B for load test.
11) Relocate scaffolding from 4201B to 4201C
12) Apply for 4201C deenergisation.
Activities achieved for the week ending Jul15
1) New & higher flowrate transformer oil filter & enclosed 12000L breaker tank arrival onsite, scaffolding-shelter setup, safety inspection.
2) Calibration certificate & manufacturing date trace for both 3rd party & MLNG oil dielectric testers; both testers found overdue for calibration
3) Simultaneous oil degradation-comparison test for both 3rd party & MLNG oil dielectric testers (IEC156 test).
4) Electrochlorination transformer 4201A tap seal repair & tap setting check.
5) Clean/repair corroded contactor at maintenance power receptacle junction box at SS19. Power receptacle used to supply power to the transformer oil filter.
6) Cover transformer oil minor oil spills (caused by sampling) with white sand.
7) Demob of old / contaminated oil filter from electrochlorination area.
8) Uncoupled runs for PM5705A/5B, MM5703at Module 1 Utility area.
9) Uncoupled runs for PM1105A/B/C at Module 1 Process area.
10) Replacement of Rotary-MEC coordinator Chang (contract expired) with Angelito Bacasmot
Activities achieved for the week ending Jul8
1) Electrochlorination transformer #1 scaffolding setup, oil pumpout (manual), new & old oil dielectric test, oxidation test.
2) Transformer oil filter test run.
3) Visual status check of Module 1 motors with Asadra (Karim).
4) Receipt of MLNG drawing BTU-40.009 (master single line diagram).
5) Receipt of MarelliMotori megger resistance acceptance criteria from vendor (FKI); 10Mohm for new motors, 1Mohm for old motors. (New motors for P-1105A/B tested at 3-8Mohm.)
6) Oven heating of P-1105A/B Marellimotori units at MLNG workshop. (Motors are 2.2kW 5.2A @ 50Hz, delta connection only.)
7) Ask MLNG which substation boilers/GTGs at Module 1 feed power to, if at all.
8) Inform Asadra & inspector on MLNG’s concern about motor uncoupled run delay. Ask why the delay is occurring.
9) Inform inspector that MLNG security instructed to use the old slugcatcher pink pass instead of the MRR contractor pass given to us. Requested the old slugcatcher pink pass be returned to us.
10) Copy process description documents from Commissioning Engineer.
11) Follow-up on MLNG operations request to check PTS requirements for number of oil samples to be withdrawn from new drums.
12) Attend confined space entry HSE lecture.
13) Nitrogen filling of electrochlorination transformer #1 to reduce water ingress. (Note: transformer couldn’t be completely emptied via handpumping; i.e. the transformer oil containment base does not seem to be flat. Oil change vendor replied verbally the 200-250L old oil remaining on the transformer was not a concern because it is below the transformer core level. KBR supervisor also informed the new oil filtration shouldn’t be done at MLNG workshop but done next to the transformer while the oil is inside, using it as a breaker tank. New oil is easily contaminated during transport out to in back into drums. KBR supervisor also expressed concern the transformer’s original tapping setting was not marked by MLNG prior to removal. KBR supervisor did not approve the transformer oil change procedure for the above reasaons but was overridden by MLNG; his recommended practice was to facbricate a drain plug, drain, and cut off the transformer top head to perform a visual inspection of the core prior to rewelding back and filling with new oil & Nitrogen filling)
Activities achieved for the week ending Jun24
1) Close both verbal and official Slugcatcher III (previous project) electrical punchlist.
2) Note location of Utilities Module 1 motors to be replaced or repainted.
3) Read through electrochlorination transformer oil change procedure.
4) Introduction to MRR PMT staff Shawn Shircliffe (Buzz), Hitoshi Chikayasu, Ibrahim Siji, Aban.
5) MRR HSE induction.
6) Receipt of cabin for desk work.
7) Fill up punchcards.
1) Post overnight noload test oil sampling and dielectric test for electrochlorination transformer 4201A.
2) Overnight loaded test of transformer 4201A; tempaerature check.
3) Deenergisation of transformer 4201B.
4) Filter new oil for transformer 4201B.
5) Replace fuse & thyristor for transformer 4201A after tripping on second night of loaded operation.
6) Install new Gate Pulse Array circuit board for transformer 4201B.
7) Oil sampling and dielectric testing ofr 4201B old, new unfiltered and new filtered oil.
8) Pumpout old oil and fill-up 4201B. Post-fill oil sampling and dielectric test.
9) Re-energise 4201A and energise 4201B for no-load test.
10) Deenergise and reenergise 4201B for load test.
11) Relocate scaffolding from 4201B to 4201C
12) Apply for 4201C deenergisation.
Activities achieved for the week ending Jul15
1) New & higher flowrate transformer oil filter & enclosed 12000L breaker tank arrival onsite, scaffolding-shelter setup, safety inspection.
2) Calibration certificate & manufacturing date trace for both 3rd party & MLNG oil dielectric testers; both testers found overdue for calibration
3) Simultaneous oil degradation-comparison test for both 3rd party & MLNG oil dielectric testers (IEC156 test).
4) Electrochlorination transformer 4201A tap seal repair & tap setting check.
5) Clean/repair corroded contactor at maintenance power receptacle junction box at SS19. Power receptacle used to supply power to the transformer oil filter.
6) Cover transformer oil minor oil spills (caused by sampling) with white sand.
7) Demob of old / contaminated oil filter from electrochlorination area.
8) Uncoupled runs for PM5705A/5B, MM5703at Module 1 Utility area.
9) Uncoupled runs for PM1105A/B/C at Module 1 Process area.
10) Replacement of Rotary-MEC coordinator Chang (contract expired) with Angelito Bacasmot
Activities achieved for the week ending Jul8
1) Electrochlorination transformer #1 scaffolding setup, oil pumpout (manual), new & old oil dielectric test, oxidation test.
2) Transformer oil filter test run.
3) Visual status check of Module 1 motors with Asadra (Karim).
4) Receipt of MLNG drawing BTU-40.009 (master single line diagram).
5) Receipt of MarelliMotori megger resistance acceptance criteria from vendor (FKI); 10Mohm for new motors, 1Mohm for old motors. (New motors for P-1105A/B tested at 3-8Mohm.)
6) Oven heating of P-1105A/B Marellimotori units at MLNG workshop. (Motors are 2.2kW 5.2A @ 50Hz, delta connection only.)
7) Ask MLNG which substation boilers/GTGs at Module 1 feed power to, if at all.
8) Inform Asadra & inspector on MLNG’s concern about motor uncoupled run delay. Ask why the delay is occurring.
9) Inform inspector that MLNG security instructed to use the old slugcatcher pink pass instead of the MRR contractor pass given to us. Requested the old slugcatcher pink pass be returned to us.
10) Copy process description documents from Commissioning Engineer.
11) Follow-up on MLNG operations request to check PTS requirements for number of oil samples to be withdrawn from new drums.
12) Attend confined space entry HSE lecture.
13) Nitrogen filling of electrochlorination transformer #1 to reduce water ingress. (Note: transformer couldn’t be completely emptied via handpumping; i.e. the transformer oil containment base does not seem to be flat. Oil change vendor replied verbally the 200-250L old oil remaining on the transformer was not a concern because it is below the transformer core level. KBR supervisor also informed the new oil filtration shouldn’t be done at MLNG workshop but done next to the transformer while the oil is inside, using it as a breaker tank. New oil is easily contaminated during transport out to in back into drums. KBR supervisor also expressed concern the transformer’s original tapping setting was not marked by MLNG prior to removal. KBR supervisor did not approve the transformer oil change procedure for the above reasaons but was overridden by MLNG; his recommended practice was to facbricate a drain plug, drain, and cut off the transformer top head to perform a visual inspection of the core prior to rewelding back and filling with new oil & Nitrogen filling)
Activities achieved for the week ending Jun24
1) Close both verbal and official Slugcatcher III (previous project) electrical punchlist.
2) Note location of Utilities Module 1 motors to be replaced or repainted.
3) Read through electrochlorination transformer oil change procedure.
4) Introduction to MRR PMT staff Shawn Shircliffe (Buzz), Hitoshi Chikayasu, Ibrahim Siji, Aban.
5) MRR HSE induction.
6) Receipt of cabin for desk work.
7) Fill up punchcards.
Wednesday, July 02, 2003
MRR Module 1 electrical progress:
-electrochlorination transformer "A" barricading and sheltering
-get Rustam's (Asadra) agreement to re-megger heat trace cables after piping insulation installation per Thermion installation guide
-buy USB flashdrive to copy large process description docs from Zul's (Commissioning) PC
-get master single line diagram of MLNG plant (A1 size) from Wan Aswandi / Jalil Bujang
-visit motor workshop to witness P-1105A/B 2.2kW motors being heated in oven to remove water (motors failed megger test for coils; only 3Mohm reading; MLNG3 spec is 15Mohm minimum)
-forward SG13course/leave application forms from Naomi/En Khazin to Buzz Shircliffe's desk
-exchange phone numbers with Chan (Rotary) for witnessing of dielectric test of old and new electrochlorination transformer oil at Sesco tomorrow.
-Boiler 5130 insulation has yet to be completely removed for heat tracing cable installation. Boiler 5120 heat tracing cables have been installed, meggered and are ready for piping insulation installation.
-Read up contract scope for HV switchgear modification at SS1 and 17 (AVR & UPS upgrade)
Zul is concerned on late construction handover to his commissioning team; he only has a month left to commission Module 1 but it hasn't been handed over from construction yet.
Conversation extract with Chika today:
"Adam-san, do you know what Salim did today."
"..No. Should I?"
(frowning) "No."
"Is there anything you'd like us to do?"
(shaking head) "No."
"Well, if there's anything you'd like us to do, let us know.."
(Terminator-style) "Have a nice day."
-electrochlorination transformer "A" barricading and sheltering
-get Rustam's (Asadra) agreement to re-megger heat trace cables after piping insulation installation per Thermion installation guide
-buy USB flashdrive to copy large process description docs from Zul's (Commissioning) PC
-get master single line diagram of MLNG plant (A1 size) from Wan Aswandi / Jalil Bujang
-visit motor workshop to witness P-1105A/B 2.2kW motors being heated in oven to remove water (motors failed megger test for coils; only 3Mohm reading; MLNG3 spec is 15Mohm minimum)
-forward SG13course/leave application forms from Naomi/En Khazin to Buzz Shircliffe's desk
-exchange phone numbers with Chan (Rotary) for witnessing of dielectric test of old and new electrochlorination transformer oil at Sesco tomorrow.
-Boiler 5130 insulation has yet to be completely removed for heat tracing cable installation. Boiler 5120 heat tracing cables have been installed, meggered and are ready for piping insulation installation.
-Read up contract scope for HV switchgear modification at SS1 and 17 (AVR & UPS upgrade)
Zul is concerned on late construction handover to his commissioning team; he only has a month left to commission Module 1 but it hasn't been handed over from construction yet.
Conversation extract with Chika today:
"Adam-san, do you know what Salim did today."
"..No. Should I?"
(frowning) "No."
"Is there anything you'd like us to do?"
(shaking head) "No."
"Well, if there's anything you'd like us to do, let us know.."
(Terminator-style) "Have a nice day."
Monday, June 30, 2003
MRR Module 1 electrical progress today:
-Heat tracing cables labelled, meggered, continuity checked from distribution JB to thermostat JBs
-Window shopped at Medan Jaya for cheapo communist bicycles to travel MLNG's mammoth site faster instead of on foot
-Re-applied to attend SG13 courses via Buzz; who will be back Jul 3.
-E-mailed various MLNG staff for Module 1-3 electrical single line diagrams and electrical/instrument/process operting manuals
MGGPillai mentioned in his article (see link below) that DBKL has a famous author among their roadsweepers. Interestingly, 2 years ago I remember getting lost on Jln Ampamg looking for Akedemi Seni Kebangsaan & stopped to desperately ask a DBKL roadsweeper. He gave excellent directions in with a friendly smile; perfect spoken English. That guy could've been him. In Bintulu you'd be lucky to find a local in town who can speak English. But interestingly, most Bintulu public libraries have an excellent collection of Chinese literature. Unfortunately I can't read Chinese characters. The Dilbo engineer in me tells me not to fret; someday I'd be able to carry a handheld scanner that could translate Chinese text on the fly.
-Heat tracing cables labelled, meggered, continuity checked from distribution JB to thermostat JBs
-Window shopped at Medan Jaya for cheapo communist bicycles to travel MLNG's mammoth site faster instead of on foot
-Re-applied to attend SG13 courses via Buzz; who will be back Jul 3.
-E-mailed various MLNG staff for Module 1-3 electrical single line diagrams and electrical/instrument/process operting manuals
MGGPillai mentioned in his article (see link below) that DBKL has a famous author among their roadsweepers. Interestingly, 2 years ago I remember getting lost on Jln Ampamg looking for Akedemi Seni Kebangsaan & stopped to desperately ask a DBKL roadsweeper. He gave excellent directions in with a friendly smile; perfect spoken English. That guy could've been him. In Bintulu you'd be lucky to find a local in town who can speak English. But interestingly, most Bintulu public libraries have an excellent collection of Chinese literature. Unfortunately I can't read Chinese characters. The Dilbo engineer in me tells me not to fret; someday I'd be able to carry a handheld scanner that could translate Chinese text on the fly.
Sunday, June 29, 2003
MGGPillai posted a very good article yesterday at http://mggpillai.com/article.php3?sid=1706 ; on reading habits of Malaysians. I bought Lord of The Rings in, like, May, and am only at the part where Frodo runs into Tom Bombadil. I think it's slower going that David Eddings' books because the characters seem too innocent. Silk, Velvet, and yes, even Garion were somehow a lot more curious and interesting.
MRR Module 1 progress thus far:
-intro to staff Shawn "Buzz" Shircliffe, Aban Slie, Hitoshi Chikayasu, Ibrahim Siji. (Salim Hashim was on board a month earlier.)
-located ("eyeballed") 10 of 59 motors being overhauled/installed
-HSE induction
-Chika & Aban showed me the electrochlorination transformers' location in anticipation for oil change by vendor tomorrow. They're a good 5-10 minute drive from Module 1, which translates into a 30 minute walk. Only 1 of the 4 transformers will be have an oil change by the Mitsubishi representative. If the 1st transformer oik change results in a safely operating transformer, our contractor Rotary will perform the oil change for the remaining 3. Buzz did not approve the Mitsubishi rep's procedure because the transformer spec plate stated NA for oil change, but Owmer overrided him & thus our job is now to just observe the rep perform the oil change at the manufacturer/Owner's risk.
A cabin to sit in came in the past week. Module 1 itself is a 10 minute walk from the MRR cabin area. No phones or computers yet. have to e-mail from home. Another disadvantage of MRR relative to the slugcatcher project is that no photos/cameras/phones allowed. And no vehicles allowed unless I get a temporary daily permit, which I have to queue up for. Might shop for a bicycle tomorrow after work.
MRR working hours are very tiring; M-F 6.30am-5.45pm, with a 12-12.45 lunchbreak; Sa 6.30am-2pm with no lunchbreak. I seem to be dozing off in the office for lack of sleep, heat and longdistance walks. The corroding bolt painting effort resulted in a dark tan on the arms & neck. I also have a light patch where my watch and hardhat goes.
Saturday was a movie day; saw both Charlie's Angels & The Hulk at Sky Cineplex. It was a good Sunday today; practised almost all useful pieces. The Grease "Summer Nights" playalong went exceptionally well, and got in an hour of swimming, squash, basketball combined. Some small boys came to hijack my ball for a while. Sat back, stretching while amusedly watching their unstructured play. I think they threw higher than I did when I was their age.
-intro to staff Shawn "Buzz" Shircliffe, Aban Slie, Hitoshi Chikayasu, Ibrahim Siji. (Salim Hashim was on board a month earlier.)
-located ("eyeballed") 10 of 59 motors being overhauled/installed
-HSE induction
-Chika & Aban showed me the electrochlorination transformers' location in anticipation for oil change by vendor tomorrow. They're a good 5-10 minute drive from Module 1, which translates into a 30 minute walk. Only 1 of the 4 transformers will be have an oil change by the Mitsubishi representative. If the 1st transformer oik change results in a safely operating transformer, our contractor Rotary will perform the oil change for the remaining 3. Buzz did not approve the Mitsubishi rep's procedure because the transformer spec plate stated NA for oil change, but Owmer overrided him & thus our job is now to just observe the rep perform the oil change at the manufacturer/Owner's risk.
A cabin to sit in came in the past week. Module 1 itself is a 10 minute walk from the MRR cabin area. No phones or computers yet. have to e-mail from home. Another disadvantage of MRR relative to the slugcatcher project is that no photos/cameras/phones allowed. And no vehicles allowed unless I get a temporary daily permit, which I have to queue up for. Might shop for a bicycle tomorrow after work.
MRR working hours are very tiring; M-F 6.30am-5.45pm, with a 12-12.45 lunchbreak; Sa 6.30am-2pm with no lunchbreak. I seem to be dozing off in the office for lack of sleep, heat and longdistance walks. The corroding bolt painting effort resulted in a dark tan on the arms & neck. I also have a light patch where my watch and hardhat goes.
Saturday was a movie day; saw both Charlie's Angels & The Hulk at Sky Cineplex. It was a good Sunday today; practised almost all useful pieces. The Grease "Summer Nights" playalong went exceptionally well, and got in an hour of swimming, squash, basketball combined. Some small boys came to hijack my ball for a while. Sat back, stretching while amusedly watching their unstructured play. I think they threw higher than I did when I was their age.
