JOB NO.

SMR-10024

PROSEDUR KOMMISIONING PEKERJAAN SHIP UNLOADER DARI PLTU INDRAMAYU KE PLTU 2 LABUAN

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DOC NO. 06/SEMITER/PLNLONTAR/I/2013

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PROYEK CLIENT

: RELOKASI SHIP UNLOADER dari PLTU INDRAMAYU KE PLTU LABUAN : PT. PLN (Persero) Pembangkitan Lontar

CONTRACTOR : PT. SEMITER LOKASI : LABUAN, PANDEGLANG - BANTEN

REV.

DESCRIPTION

DATE

PREPARED

CHECKED

APPROVED

JOB NO. SMR-10024

PROSEDUR KOMMISIONING PEKERJAAN SHIP UNLOADER DARI PLTU INDRAMAYU KE PLTU 2 LABUAN

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DOC NO. 06/SEMITER/PLNLONTAR/I/2013

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Table Of Content 1. Purose 2. Precondition for commissioning 3. Trial operation without load 4. Trail operation with load 5. Appendix 1 15

JOB NO. SMR-10024

PROSEDUR KOMMISIONING PEKERJAAN SHIP UNLOADER DARI PLTU INDRAMAYU KE PLTU 2 LABUAN

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DOC NO. 06/SEMITER/PLNLONTAR/I/2013

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1. Purpose The purpose of this procedure is used to guide bridge grab bucket ship unloader commissioning, ensure that main and auxiliary equipment are safe and normal operation performance, which can meet the design requirement. Refer to appendix 1 : Data sheet of ship unloader 2. Precondition for commissioning 2.1 2.2 2.3 Equipment installation is completed. All electric equipments are on power There is no defect on equipment appearance.

2.4 There is no defect on drive mechanism. Add grease to handspikes, speed reducers and hydraulic statioan. Shaft bearing of speed reducer is flexible. 2.5 2.6 2.7 2.8 Oil level of speed reducer is up to mark of oil level meter. Safety facility is ready and emergency button is reliable. There is enough light at site There are good communication equipments for commissioning. Refer to Appendix 2: Check list of necessary precondition for detail 3. Trial operation without load 3.1 Trial operation of travel mechanism and reel

The ship unloaders travel mechanism can be moved forward and backward smoothly on rail. Pulling and discharging of cable reel is normal. Refer to Appendix 3: check list of travel mechanism function for detail 3.2 Four drum echanism Each drum can be rotated smoothly and the brake is reliable. The motors and drums of grab bucket for hoisting and on/off function are working correctly. The travelling trolley of the grab bucket is working corretly. Both are working comformably to make sure the garab bucket can complete various actions. Refer to Appendix 4: Check list of Four-drum mechanism function for detail

JOB NO. SMR-10024

PROSEDUR KOMMISIONING PEKERJAAN SHIP UNLOADER DARI PLTU INDRAMAYU KE PLTU 2 LABUAN

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DOC NO. 06/SEMITER/PLNLONTAR/I/2013

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3.3

Cabin

Cabin can be moved to sea side and land side freely along rail, can be stopped at any necessary position. Cabin can be stopped automatically at limit position. Refer to Appendix 5: Check list of Cabin function for detail 3.4 Coal Feeding system Coal feeder can be running normally. Function of auxiliary devices in coal feeding system is normal. Refer to Appendix 6: Chek list of Coal Feeding system. 3.5 Derricking mechanism Rotating direction of drum motor is correct and the brake is realible. Boom derricking can be completed in 16 minutes. Refer to Appendik 7: Check list Derricking mechanism function 3.6 Power break test Brakes act immediately while power break down Refer to Appendik 9: Power break test 3.7 Motor Test AC Motor test Refer to Appendik 10 3.8 Ove speed test and high wind test Refer to Appendix 11 3.8 Seting value and Logic diagram Major motor Protection Parameters Stting Value Refer to Appendix 12 Sequence and Motion start and stop interlock logic diagram Refer to Appendix 13

JOB NO. SMR-10024

PROSEDUR KOMMISIONING PEKERJAAN SHIP UNLOADER DARI PLTU INDRAMAYU KE PLTU 2 LABUAN

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DOC NO. 06/SEMITER/PLNLONTAR/I/2013

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Trolley cabin interlock witch boom Refer to Appendix 14 Protection value set Refer to Appendix 15 3.10 Operation mode Local operation: Operate gantry in gantry local control box; operate hopper in hopper local control box; operate boom local control box. Manual operation: Operate grab in cabin manually. Semi-auto operation: Operation grab in cabin automaticly, the grab move to the hopper and open automaticly, and go back to the same position it starts. 4. Trail operation with load 4.1 Trail operation with load

The ship unloader can trail run with load when coal transfer system trail operation is completed and the coal barge has reached jetty. After the trail operation witch load is completed, the capability test of ship unloader can be taken. 4.2 Rated capacity Rated capacity: 1250 T/h ( coal bulk density: 800 kg/m ) Rated capacity means the output capacity in the following conditions: (1) (2) 4.3 Test method The coal in the barge can be easy to load. The coal level in the barge should be 50% AL LEAST;

In the condition that the operator is skilled enough and bunkers material level could satisfy the grab bucket to catch raw material continuously, this ship unloader work at least 30 min continuously. Measure the trhoughtput per 20 min by belt scale to achieve the instaneous capacity and rated capacity of ship unloader. Refer to appendix 8 Capability test record

JOB NO. SMR-10024

PROSEDUR KOMMISIONING PEKERJAAN SHIP UNLOADER DARI PLTU INDRAMAYU KE PLTU 2 LABUAN

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DOC NO. 06/SEMITER/PLNLONTAR/I/2013

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Appendix 2 Check list of necessary pre condition Unit: Com System name: Bridge grab bucket ship unloader date:___

No

Requirement
Main breaker and branch switches are normal and the power is on. All limit switches is installed and adjusted. No break on equipment appearance. There is no defect on travel mechanism. Add lubricant to handspikes, decelerators and hydraulic station. Shaft bearing of speed reducer is flexible. Oil level of speed reducer is reliable. Control and interlock loop have been installed and adjusted. The operation, interlock and alarm is reliable. Scaffod is removed and the path is even. Safety facility is ready and emergency button is reliable. There is enough light at site. There are good communication equipmens for commissioning.

Result

1 2 3 4

5 6 7 8 9 10

Remarks:

COMPLETED BY NAME SIGNATURE DATE

PT. SEMITER

PT. REKADAYA ELEKTRIKA

PT. PLN (Persero)

JOB NO. SMR-10024

PROSEDUR KOMMISIONING PEKERJAAN SHIP UNLOADER DARI PLTU INDRAMAYU KE PLTU 2 LABUAN

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DOC NO. 06/SEMITER/PLNLONTAR/I/2013

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Appendix 3 Check list of travel mechanism function Unit: Com System name: Bridge grab bucket ship unloader date:___

No

Description
Operate crane on local Anti-creeper function Stop limit function

Requirement
Crane travel normally and no block and breakdown. The anti-creeper can automatically lift when crane is travelling More than 30 cm from damper when crane stops.

Result

1 2 3

Cable reel pulling and Pulling when mechanism is discharging function moving to jetty transfer tower and discharging when moving to the opposite direction. The cable is not confusion.

Alarm light

Alarm lighting to alarm when crane is travelling.

Remarks:

COMPLETED BY

PT. SEMITER

PT. REKADAYA ELEKTRIKA

PT. PLN (Persero)

NAME SIGNATURE DATE

JOB NO. SMR-10024

PROSEDUR KOMMISIONING PEKERJAAN SHIP UNLOADER DARI PLTU INDRAMAYU KE PLTU 2 LABUAN

REV

DOC NO. 06/SEMITER/PLNLONTAR/I/2013

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Appendix 4 Check list of Four-drum mechanism function Unit: Com System name: Bridge grab bucket ship unloader date:___

No

Description

Requirement
The crab crane mechanism will stop automatically when moving to limit position

Result

Terminal limit function The lifting mechanism will stop automatically when lifting to limit positioan. Operation function of bucket and crab crane mechanism in control cabin The interlock functions of oil pump of speed reducer Buldozer function test Start four-drum mechanism working to make grab lifting and on-off; to make crab crane moving. Oil pump is synchronized ruuning with drum running. In bulldozer operation mode, the grab position is over 4.5 meters from hopper when it stops in up limit

Remarks:

COMPLETED BY

PT. SEMITER

PT. REKADAYA ELEKTRIKA

PT. PLN (Persero)

NAME SIGNATURE DATE

JOB NO. SMR-10024

PROSEDUR KOMMISIONING PEKERJAAN SHIP UNLOADER DARI PLTU INDRAMAYU KE PLTU 2 LABUAN

REV

DOC NO. 06/SEMITER/PLNLONTAR/I/2013

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Appendix 5 Check list of cabin function Unit: Com System name: Bridge grab bucket ship unloader date:___

No

Description
Cabin moving function

Requirement
The cabin moves from land side to sea side one shuttle with no block and breakdown. The cabin will stop automatically when the cabin moves to limit position. Normal.

Result

1 Stop limit function 2 3 Bell and loudspeaker

Remarks:

COMPLETED BY

PT. SEMITER

PT. REKADAYA ELEKTRIKA

PT. PLN (Persero)

NAME SIGNATURE DATE

JOB NO. SMR-10024

PROSEDUR KOMMISIONING PEKERJAAN SHIP UNLOADER DARI PLTU INDRAMAYU KE PLTU 2 LABUAN

REV

DOC NO. 06/SEMITER/PLNLONTAR/I/2013

0.

Appendix 6 Check list of feeding mechanism function Unit: Com System name: Bridge grab bucket ship unloader date:___

No

Description
Local control function of feeding motor Local control function of striking motor

Requirement
Start and stop feeding motor on local. The feeding motor is working normally. Start and stop striking motor on local. The striking motor is working normally.

Result

Remote control function Start and stop feeding motor in of feeding motor cabin. The feeding motor is working normally. Remote control function Start and stop striking motor in of striking motor cabin. The striking motor is working normally.

Remarks:

COMPLETED BY

PT. SEMITER

PT. REKADAYA ELEKTRIKA

PT. PLN (Persero)

NAME SIGNATURE DATE

JOB NO. SMR-10024

PROSEDUR KOMMISIONING PEKERJAAN SHIP UNLOADER DARI PLTU INDRAMAYU KE PLTU 2 LABUAN

REV

DOC NO. 06/SEMITER/PLNLONTAR/I/2013

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Appendix 7 Check list of Derricking mechanism function Unit: Com System name: Bridge grab bucket ship unloader date:___

No

Description

Requirement

Result

Operate safety hook on Safety hook is normal with correct local limit Interlock function Derricking mechanism cannot work when crab crane and cabin is on sea side. Less than 16 minuts when lifting

Dericking on local

The brake is normal Realising chord switch is normal

Up limit test

Up limit switch works probably

Remarks:

COMPLETED BY

PT. SEMITER

PT. REKADAYA ELEKTRIKA

PT. PLN (Persero)

NAME SIGNATURE DATE

JOB NO. SMR-10024

PROSEDUR KOMMISIONING PEKERJAAN SHIP UNLOADER DARI PLTU INDRAMAYU KE PLTU 2 LABUAN

REV

DOC NO. 06/SEMITER/PLNLONTAR/I/2013

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Appendix 8 Capability test record Unit: Com System name: Bridge grab bucket ship unloader date:___

Item
Material throughput Rated capacity Remarks: T/20min T/h

Unit

Result

Rated capacity: 1250T/h (coal stacking unit weight: 800kg/m3) Rated capacity means the output capacity in the following conditions: (1) The coal in the barge can be easy to unload (2) The coal level in the barge should be 50% al least; Rated capacity (T/h)= material throughput (T/20min)x3 Test method: In the condition that the operator is skilled enough an bunkers material level could satisfy the grab bucket to cath raw material continuously, this ship unloader works at least 30 min continuously. Measure the troguhput per 20 min by belt scale to achieve the instaneous capacity and rayed capacity of ship unloader. Date:________ Start time 1: _________ Finish time 1: ________ Take time : _________ Coal Weight : ________ Start time 2: _________ Finish time 2: ________ Take time : _________ Coal Weight : ________

COMPLETED BY

PT. SEMITER

PT. REKADAYA ELEKTRIKA

PT. PLN (Persero)

NAME SIGNATURE DATE

JOB NO. SMR-10024

PROSEDUR KOMMISIONING PEKERJAAN SHIP UNLOADER DARI PLTU INDRAMAYU KE PLTU 2 LABUAN

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DOC NO. 06/SEMITER/PLNLONTAR/I/2013

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Appendix 9 Power break test Unit: Com System name: Bridge grab bucket ship unloader date:___

No
Holding Closing Boom

Item

Requirement
Brake act immediately after power break Brake act immediately after power break Brake act immediately after power break

Result

1 2

Remarks:

COMPLETED BY

PT. SEMITER

PT. REKADAYA ELEKTRIKA

PT. PLN (Persero)

NAME SIGNATURE DATE

JOB NO. SMR-10024

PROSEDUR KOMMISIONING PEKERJAAN SHIP UNLOADER DARI PLTU INDRAMAYU KE PLTU 2 LABUAN

REV

DOC NO. 06/SEMITER/PLNLONTAR/I/2013

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Appendix 10 AC MOTOR TEST REPORT Usage purpose 1. Nameplate Type Rated voltage Frequency Conection Symbol Rev (r/min) Manufacturer 2. Test Polarity: U1 , V1 , W 1 Same polarity Applied instrument: MF14 Multimeter operation 3. Test temperature Trail operation without load: 4. Test vibration Uncouple; 5. Test insulation Resistance Insulation Resistance (G ) Windings U-V W & G V-U W & G W-U V & G Applied instrument: UT512/1000V R 15 R 60 Couple; Trail operation with load: Rated capacity Rated current LW (dB) Ex-factory date Equipment Code Instalation location

JOB NO. SMR-10024

PROSEDUR KOMMISIONING PEKERJAAN SHIP UNLOADER DARI PLTU INDRAMAYU KE PLTU 2 LABUAN

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DOC NO. 06/SEMITER/PLNLONTAR/I/2013

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6. Test Resistance: Windings Resistance () Applied instrument: Multimeter 7. Test Conclusion: OK Tested Date Temperature U1-U2 V1-V2 W1-W2

Date: ____________ Tested By:

Date: ____________ Approved By:

Date: ____________ Witnessed By:

PT. SEMITER

PT. REKADAYA ELEKTRIKA

PT. PLN (Persero)

JOB NO. SMR-10024

PROSEDUR KOMMISIONING PEKERJAAN SHIP UNLOADER DARI PLTU INDRAMAYU KE PLTU 2 LABUAN

REV

DOC NO. 06/SEMITER/PLNLONTAR/I/2013

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Appendix 11 Over speed and high wind protection test Unit: Com System name: Bridge grab bucket ship unloader date:___

No

Description

Requirement

Result

1 2

The holding over speed Power break switch conection break The closing over speed Power break switch conection break The bomm over speed switch conection break High wind Power break

Power break, can only operate gantry in local control box.

Remarks:

COMPLETED BY

PT. SEMITER

PT. REKADAYA ELEKTRIKA

PT. PLN (Persero)

NAME SIGNATURE DATE

JOB NO. SMR-10024

PROSEDUR KOMMISIONING PEKERJAAN SHIP UNLOADER DARI PLTU INDRAMAYU KE PLTU 2 LABUAN

REV

DOC NO. 06/SEMITER/PLNLONTAR/I/2013

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Appendix 12 Major Motor Protection Parameters Setting Value Unit:_____ System name: Bridge grab bucket ship unloader date:___

No
1 2

Item
Gantry Motor Holding Motor

Max Current Set Value

240A CW: 150% = CCW: 150% = CW: 150% =

Max Torque Set Value

CW: 160% CCW: 160% CW: 160% CCW: 160% CW: 150% CCW: 150% CW: 150% CCW: 150%

Closing Motor CCW: 150% = CW: 130% =

Trolley Motor CCW: 130% = CW: 130% =

Boom Motor CCW: 130% =

Remarks:

COMPLETED BY

PT. SEMITER

PT. REKADAYA ELEKTRIKA

PT. PLN (Persero)

NAME SIGNATURE DATE

JOB NO. SMR-10024

PROSEDUR KOMMISIONING PEKERJAAN SHIP UNLOADER DARI PLTU INDRAMAYU KE PLTU 2 LABUAN

REV

DOC NO. 06/SEMITER/PLNLONTAR/I/2013

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Appendix 13 Sequence and Motion start and stop interlock Unit:_____ System name: Bridge grab bucket ship unloader
Gantry no Fault, reliable

date:___

Lubricate system normal

Steel wire no Fault, reliable

Steel wire no Fault, reliable

Steel wire no Fault, reliable

Power system Fault, reliable

Steel wire no Fault, reliable

Drive, brake system normal

Limit switch normal

1. Holding
Holding hoist up by master contoller System No fault UP Stop LS No Action Hoist UP

Holding hoist Down by master contoller

System No fault

Down Stop LS No Action

Hoist Down

2. Closing
Closing by master controller System No fault Close > init value Closing Grab

Opening by master controller

System No fault

Close < init value

Opening Grab

JOB NO. SMR-10024

PROSEDUR KOMMISIONING PEKERJAAN SHIP UNLOADER DARI PLTU INDRAMAYU KE PLTU 2 LABUAN

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DOC NO. 06/SEMITER/PLNLONTAR/I/2013

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3. Trolley
Trolly seaside by master controller System s No fault & Trolley latch & boom level Up stop is no action & rope loose is no action Boom up running

Trolly landside by master controller

System s No fault & Trolley latch & boom level

Down stop is no action & rope loose is no action

Boom down running

4. Travelling
Gantry forward by cabin or local System s No fault & anchor realese Forward Stop LS No Action Gantry forward running

Gantry backward by cabin or local

System s No fault & anchor realese

Backward Stop LS No Action

Gantry backward running

COMPLETED BY

PT. SEMITER

PT. REKADAYA ELEKTRIKA

PT. PLN (Persero)

NAME SIGNATURE DATE

JOB NO. SMR-10024

PROSEDUR KOMMISIONING PEKERJAAN SHIP UNLOADER DARI PLTU INDRAMAYU KE PLTU 2 LABUAN

REV

DOC NO. 06/SEMITER/PLNLONTAR/I/2013

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Appendix 14 trolley & cabin interlock with boom Unit:_____ System name: Bridge grab bucket ship unloader date:___

Boom Level

Trolley Permission

Rolley & Cabin Parked

Boom Permission

The trolley can only move while the boom (derricking mechanism) levels. The boom can only lift while trolley and cabin parked.

COMPLETED BY

PT. SEMITER

PT. REKADAYA ELEKTRIKA

PT. PLN (Persero)

NAME SIGNATURE DATE

JOB NO. SMR-10024

PROSEDUR KOMMISIONING PEKERJAAN SHIP UNLOADER DARI PLTU INDRAMAYU KE PLTU 2 LABUAN

REV

DOC NO. 06/SEMITER/PLNLONTAR/I/2013

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Appendix 15 Protection motion Value setting Unit:_____ System name: Bridge grab bucket ship unloader 2# date:___

No

Item

Description
Sea side over travel switch Sea side stop limit switch Sea side slow down is

Value
1 1 1 %Md696 < 11000 %Md696 < 5000 %Md696 < 3100 Both 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Trolley

Sea side soft slow down Land side soft slow down 1 Land side soft slow down 2 Land side stop and overtravel Up slow down Is Up stop Is

Holding

Buldozer mode Up stop Up over travel Lower stop Is Up stop Is Buldozer mode Up stop

3 Up over travel Lower stop Is Up stop Is Up over travel 4 Boom Rope loose Boom plant Drum emty

JOB NO. SMR-10024

PROSEDUR KOMMISIONING PEKERJAAN SHIP UNLOADER DARI PLTU INDRAMAYU KE PLTU 2 LABUAN

REV

DOC NO. 06/SEMITER/PLNLONTAR/I/2013

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High wind

High wind speed

21 m/s`

%Md696 is the trolley position value (trough the encoder) The limit switch value 1 means its in normal status, for example, if trolley seaside slow down limit switch is induced, the value is changes to 0

COMPLETED BY

PT. SEMITER

PT. REKADAYA ELEKTRIKA

PT. PLN (Persero)

NAME SIGNATURE DATE