1

CHAPTER I

INTRODUCTION

Internship or On-the-Job Training (OJT) is one method by which a student is given a

chance to apply theories and gain hands-on experiences. It also gives the trainee an

opportunity to acquire knowledge and enhance their skills by performing tasks and be

exposed with different work stations. OJT is a part of the Central Philippine State

University curriculum that aims to prepare and equip students for global competition after

graduation.

As it is known, most of the knowledge and skills can be learned on the workplace,

proper work attitude is also formed at work. This cannot be taught by the school but can

be experienced during the On-the-Job training.

The electrical engineering students of Central Philippine State University is required

to undergone their internship or On-the-Job Training for two hundred forty (240) hours as

required by the curriculum. This would help the students to broaden their skills, and

productivity by exposing them in the field of work where they would be able to

experience the reality about working, it would also build their social relationship by

dealing with different people in its workplace.

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Objectives

The objectives of the 240 hours On-the-Job training that the student trainee should

meet throughout the duration of the actual field of practice were the following:

1. Train the students in the application of Electrical Engineering principles.

2. Prepare them to become professionals with entry-level competencies.

3. Conduct an actual hands-on on different equipment.

4. Perform an evaluation on Electrical equipment based on Philippine Electrical

Code.
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CHAPTER II

PROCEDURE

This chapter presents the process and preparation undertaken by the student trainee

before his On-the-Job training. This includes the selection of firms, sending of

communication, school orientation, the date and time of departure from the school,

arrival at the selected firm and the company orientation.

Selection of Firm

The trainee chose the Universal Robina Corporation (URC) sugar milling company

as a venue to undergo for his OJT. The first company he choose was Southern Negros

Development Corporation (SONEDCO) located at Brgy. Camugao, Kabankalan City,

Negros Occidental, and the second was the Universal Robina Corporation Sugar and

Renewables (URC SURE Tolong) Division located at Brgy. Caranoche, Sta. Catalina,

Negros Oriental.

It was December 2019, when Engr. Rene T. Dagunan, Dean of College of

Engineering oriented all the fourth year engineering students about their upcoming OJT.

He discussed regarding the importance of the Memorandum of Agreement (MOA).

Since the SONEDCO would not sign the MOA the trainee’s reservation had been

canceled.

The trainee then decided to undergo his On-the-Job training at the URC-SURE

Tolong, for this prestigious company was known for its quality training, competency and

warm accommodation to their trainees. He believed that this company can contribute a
 4

decent and sufficient experience in the actual practices.

Sending of communication

With the help and efforts of their adviser as well as their OJT coordinator, Engr.

Alberto R. Deliña, the trainee with his co-trainee brought the OJT letter of

communication, endorsement letter and draft of Memorandum of Agreement to Universal

Robina Corporation Sugar and Renewables (URC-SURE) Tolong on February 2, 2019.

The said letter was accepted by Ms. Antoinette Eullaran, the OIC HR Manager. She

informed the trainees about the requirements and documents needed before the training

started. On March 26, the trainees went back to submit their documents and the

requirements to Mrs. Asela Grace Arañes, the HR manager.

Orientation by the school

Engr. Rene T. Dagunan, Dean of College of the Engineering conducted an

orientation to the upcoming OJT students in the three engineering courses namely; BS

Agricultural Engineering, BS Mechanical Engineering and BS Electrical Engineering for

the summer 2018-2019. The orientation was conducted last March 18, 2019 in the

Engineering building. He discussed about the proper attitude, taking of notes especially

the specifications of equipment, machinery and to learn the application of the course on

the actual field of work. He emphasized also the things that should be avoided that may

negatively affect the reputation and image of the University and its personnel.

Also, on March 27, Engr. Alberto R. Deliña, Ma.Eng, Adviser and OJT coordinator
 5

of Electrical Engineering oriented the trainees and discussed the things that should be

done during OJT, the importance of MOA, OJT logbook and OJT journal. The trainees

had been reminded regarding of their documents that should be submitted before their

OJT started.

Departure

On the 5th day of April 2019 the trainee departed from CPSU at exactly 3:00 o’clock

in the afternoon. He brought with him the PPE’s required by the company, the notarized

MOA and his personal belongings.

Arrival

After almost two and a half hours of travel the trainee arrived at Bayawan City,

Negros Oriental at exactly 5:30 in the afternoon.

Company Orientation

On April 8 2019, the trainee arrived at the URC-SURE Tolong together with his co-

trainee. They directly reported to Ms. Antoinette Eullaran, the OIC HR Manager, in the

HR office. Ms. Eullaran checked the required documents and the Personal Protective

Equipments (PPE’s) of the trainee. Afterward, the trainee was referred to the safety office

for the safety orientation. The Orientation was conducted by Engr. Niño Ramon

Cristhopher Cordova, Safety officer, Engr. Narcis Omar Lorno, Pollution control officer
 6

and Ma.am Jogie E. Coniedo, Customer Care Officer. They discussed the rules and

regulations of the company that should be followed by the trainees, the importance of

safety was greatly emphasized in the orientation. Most especially the proper protective

equipment such as googles, mask, vest, steel toe shoes and hard hats was indicated. The

trainees was also instructed on using of fire extinguisher and the assembly area in case of

emergency. After the safety orientation, Ms. Antoinette Eullaran presented a short video

about the company’s background, mission, vision, quality policy, history, and the

products produced. On the afternoon Engr. Arturo Silva Jr, EE OJT coordinator, finalized

the trainees schedules during the 240 hours of training and toured the trainee to the areas

under the electrical department. Also Ma’am Jogie E. Coniedo toured the trainee to the

whole factory and introduce him to the shift supervisors who were in-charge in every

department.

CHAPTER III
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BACKGROUND OF THE COMPANY

This chapter present the history, mission, vision, mandate, quality policy, core

values and the quality objectives of the company.

History

URC-SURE TOLONG is one of the six mills under the Universal Robina

Corporation Sugar and Renewables (URC SURE) Division. It is a Raw Sugar Mill with

main office at Suite 2201 Robinsons Equitable Tower No. 4 ADB Avenue Corner Poveda

Street Ortigas Center, Pasig City and plant site at Brgy. Caranoche, Sta. Catalina, Negros

Oriental. The raw sugar mill was constructed in 1969, was known as Tolong Sugar

Milling Company (TSMC) and was owned originally by a group sugar planters in the

district. In 1988, TSMC was acquired by then Congressman Herminio G. Teves and the

name was changed to Herminio Teves & Company, Inc. (HTCI). The plant was acquired

by Universal Robina Corporation in October 2012, hence its new name. The mill was

originally a conventional type with three (3) sets of cane knives. It has expanded its

milling capacity of 4000 tons cane per day from 3000TCD to be able to meet the increase

in cane production of the district.

In the last 4 years, URC SURE TOLONG has introduced several improvements in

the factory that tantamount to increased efficiency, capacity and improved quality of the

product. It has also employed automation of systems processes in some critical areas like
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the control panels, vacuum pans, evaporators, laboratory data, materials requisition and

issuances, sugar system automation and sugar withdrawal.

The principal finished product is raw sugar. It is stored as bulk sugar in sugar

warehouse of the plant. It can be withdrawn either in bags or in bulk by sugar trader/s or

planter/s depending on the required specification. The final molasses which is a by-

product in the manufacturing process is stored in the molasses tank at plant site.

The canes milled are owned by the planters in the area and delivered to the mill by

trucks owned or hired by the planters. To assist in the planters hauling the canes to the

mill, the company provides free hauling assistance in the form of company owned

hauling trucks.

To stay afloat in an industry with very stiff competition, URC SURE TOLONG

participated in a sugar trading which helped its sugar traders remain in business and made

planters to remain loyal to the company and also helped maintain and uplift the social and

economic plight of the district where URC SURE TOLONG belongs.

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Vision

We are the biggest, most preferred producer and supplier of diversified sugarcane-based

products in the Philippines, developed by exceptionally competent and respected

organization.

We drive sustainable economic growth and serve as pride of communities where

we operate.

We are reputable and strong player in the ASEAN Region.

Mission

 Customers

We will excel in providing quality sugar at all times. We will provide

excellent allied services to our stakeholders.

 Business Partners

We will further enhance our relationship based on fairness and long term

viability that is mutually beneficial.

 Employees

We will continually attract and maintain the best. We will provide them

opportunities for growth, development recognition, and empowerment and we

will take care of their wellness and welfare. We will operate in a family-like

manner.

 Community

We will commit to enhance our Corporate Social Responsibility in the

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communities where we operate.

 Facilities

We will keep our facilities safe and on tip-top condition. We will

therefore, work for their continued upkeep and upgrade through state of the art

technologies.

 Owners

We will ensure stakeholders premium returns on their investment.

 Business Development and Innovation

We will look for business opportunities that add value to the company.

We will be driven by the desire to achieve and exceed our targets by continually

improving ourselves and by being open to possibilities of doing things better. We

will take on new challenges and maximize existing resources.

 Cost Management

We will exercise prudence in the use of company resources and utilize

technology to our competitive advantage.

Quality Policy

URC SURE TOLONG is committed to provide quality products and services that

consistently satisfy the needs of interested parties and to comply with applicable statutory

and regulatory requirements.

We shall produce consistently good quality raw sugar to meet customer demand at

the lowest possible production cost and shall be available for withdrawal at all times.

We shall exert efforts to ensure safety, cleanliness and orderliness of the factory.
 11

We endeavor to identify potential problems, provide preventive measure and correct non-

conformities.

We shall ensure that our operations will be beneficial to the environment and

community where we operate in.

We shall continually enhance the efficiency and effectiveness of our quality

management system by being creative and innovative in achieving our objectives and

targets through processes and product monitoring.

We shall continuously strive to improve the efficiency of the factory and the

quality of the products and this will be the responsibility of every URC SURE TOLONG

employee.to

This quality policy shall be understood, implemented and available to all

concerned internal and external interested parties.

Occupational Safety and Health (OSH) Policy

Universal Robina Corporation – Sugar & Renewables Division (URC-SURE) is

committed to provide a safe and healthy work environment through compliance with

applicable rules, regulations and standards as provided by law.

URC-SURE will provide adequate resources to implement a comprehensive occupational

safety and health program that will ensure the protection of its employees and other

stakeholders and prevent damage to equipment and other properties.

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URC-SURE will adopt proven technologies and world-class innovations and

methodologies for the continuous improvement of its safety and health performance.

URC-SURE will ensure that all its operations do not present safety and health problems

to the community where it operates.

All URC-SURE employees are aware of their roles and responsibilities for the safety and

health of everyone; are and given the appropriate training, empowerment and equipment

to meet its OSH targets and objectives.

This OSH Policy is communicated to all its stakeholders to promote a culture of safety

and health as well as the sustainability of its business.

URC-SURE Environmental Policy

Universal Robina Corporation – Sugar and Renewables Division (URC-SURE) is

committed to building and maintaining am environment-friendly and sustainable facility

by ensuring that the environment is cared for in our every activities and operations,

through compliance and conformance with applicable laws and standard, maximizing our

resources, and minimizing our wastes.

URC-SURE is dedicated to reduce environmental impact by undertaking initiatives to

attain an excellent environmental performance through:

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1. Reduction of greenhouse gasses emission, energy and water

consumption.

2. Maximizing our resources, and effective waste management

through the reutilization, recycling, reprocessing and conversion

into renewable energy.

3. Energy conservation and use of renewable energy resources.

4. Water conservation; recovery and reuse of water, and rain water

harvesting.

URC-SURE will communicate this Environmental Policy to all its stakeholders to

promote a caring attitude towards protecting and preserving the environment as well as

the sustainability of its business.

CHAPTER IV
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SYNOPSIS OF EXPERIENCE

This chapter embodies the summary of the student trainee’s activities, learnings

and experiences during his 240 hours on-the-job training at the Universal Robina

Corporation Sugar and Renewables- Tolong division (URC-SURE TOLONG) located at

Brgy. Caranoche, Sta. Catalina, Negros Oriental from April 8 to June 14, 2019.

As an Electrical Engineering student, the trainee was assigned in the Electrical

Department on its five electrical areas, the Powerhouse, Preventive Maintenance, Air-

conditioning and Instrumentation departments.

Powerhouse

The powerhouse was the center of the electrical department. It was under the

management of Engr. Roy Evans Barrera, Electrical Department manager and supervised

by the three shift supervisors namely, Engr. Matalino Cortez, Sir Patrick Teologio and

Engr. Adham Jay Taburada. Each supervisor also had five electricians assigned with

them. The student trainee was assigned on these five areas for 96 hours and was able to

observe its operation during milling season. The factory was a self-generating plant and

used its own power supply for operation. The powerhouse was in-charge of the motor

control in the plant. They also had three steam turbine generators (TG’s) (Fig1) and one

diesel generator “caterpillar” (Fig2). The steam generator received its steam from the two

boilers. The steam was stored on the steam tank before distributing it to the whole plant.

The steam turbine generator was dependent on the boiler. In case the boiler
 15

malfunctioned, the steam turbines would also be affected, so to continue the operations

they would use the supply of NORECO II that was parallel with the three turbine

generators. The three-steam turbine produced a 9000 revolutions per minute (rpm); the

speed was being reduce by the reduction gear unit (RGU) into 1,800 rpm, which was

needed by the generator to generate power, the TG1 generates a power of 2.75 MW and

the TG2 and TG3 generates 2 MW. In order for the steam turbine generator to operate it

should have the following steam condition; (1.) the steam temperature should not be less

than 300oC or 550oF, and (2.) Boiler pressure should not be less than 19 kg/cm 2, the ideal

condition temperature are 330oC and steam pressure is 21.5 kg/cm 2. The diesel generator

is only used as a backup power in case of low steam pressure (LSP). It had the rating of

1250 kVA, 1000 kW (output power) 0.8 power factor at 60 Hz and had a data of 3 phase

10 wire generator that was wired in wye or series configuration. The generator supplied

480 VAC with 1503 amps capability and required a 41 VAC at 9.1 amps to excite field

and 1800 rpm minimum required.

The student trainee was able to witness the actual operation of generating power

from the generators. Through this, the student trainee learned the operation and function

of the system, especially the importance of synchronizing the turbine generators of TG2

and TG3. Synchronizing the TG’s required them to have the same voltage and frequency

to avoid reverse power. The three turbine generators were being monitored and controlled

by a switchboard (Fig 3 and Fig 3.1) and the one that operates the switchboard is the

switchboard operator.

The student trainee was also able to observe and assist one of the electricians Sir

Darnel Villo in the ampere reading on the wires of controls, the trainee also accompanied
 16

him in checking the breaker in the reservoir. Sir Villo toured the student trainee and

introduce to them the different motors that operated in the mill department and the

student trainee was able to take pictures and specifications of motors in the milling

department.

On the next day, Sir Leonardo M. Obanana and Sir Uriah Ray T. Electona,

electricians supervised the trainee on connecting the three control. The trainee performed

connecting the three-motor control (Fig 4), the direct online (Fig 5), the forward reverse

(Fig 6) and the Wye delta (Fig 7). The electricians checked the trainee’s work afterwards.

On the following day, Engr. Matalino Cortez discussed to the trainee the principle

and operation of the turbine generator and how was the process of the steam from the

boiler being distributed to the mill and turbine generator (Fig 8). He also toured the

trainee in the plant and introduced to the different controls, motors and their operations

(FIG 9). Engr. Cortez also discussed about the function of the communication system of

HGCB and Sugar warehouse. The communication system was a bell code and it had

guides for certain codes “Morse Code” Engr. Cortez suggested about Upgrading of the

communication system that would prevent miscommunications and misinformation

between the two stations. The trainees also have given a task to design a direct online

motor control with the following data the motor is in 3 phase, 45kW and has 440V and

based it on (TABLE 1), (TABLE 2) and (TABLE 3). The trainee computed the (a.)

circuit breaker (CB) Ampere Trip rating, (b.) wire size, (c.) contactor and (d.) overload

relay. The trainee was able to design the motor control of the 45kW motor (FIG 10,

APPENDIX I). It was then checked and discussed by Engr. Matalino Cortez.

Being assigned to the powerhouse department the student trainee was able to
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observe the application of motor control and proved the theories in actual operation.

During off season repair, the trainee together with his co-trainee observed the

dismantling of the steam turbine generator and saw its internal parts. The trainee was also

able to assist, but mainly observed during this repair season.

High Grade Centrifugal Basket Station and Sugar Warehouse

During the time where the student trainee was assigned at the powerhouse, the

student trainee was given an opportunity by their supervisor to visit and observe the

different areas of the URC-SURE Tolong, one of the area is the High-Grade Centrifugal

Basket (HGCB) station. HGCB station is under the Raw Process Department and the one

that is concerned for drying the crystallized sugar before it is being send to the sugar

warehouse. Sugar-Warehouse is separated from the factory building, the dried sugar from

the HGCB is being transferred to the sugar-warehouse by the means of a conveyor. And

the dried sugar is being stacked and being packed in the sugar-warehouse.

The student trainee was able to visit and roam this two areas during their time in

the powerhouse and was able to observe its operation.

Preventive Maintenance Inspection

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The trainee was assigned in the preventive maintenance inspection in the near end

of the milling season and the person in-charge in this area was Engr. Rochelle

Tubongbanua, the preventive maintenance who was in-charge of monitoring, recording

and checking the condition of the motors and equipment while it was still working to

avoid unexpectedly break down, using the thermal imager. His work included checking

the temperature wires and checking the ventilation of the motors. The trainees were

toured and introduced to the different equipment that was under the care of the PMI,

Engr. Tubongbanua who demonstrated to the trainee how to monitor the temperature and

how to check the ventilation of the motors and equipment.

On the last of duty, under the supervision of Engr. Kent Joseph Coloyan,

demonstrated how to use the thermal imager.

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Motor Rewinding Center (MRC)

Motor rewinding center was assigned in the repairing and rewinding of burned

motors. URC tolong was the only plant under the Universal Robina Corporation in

Negros Oriental and Occidental that had a rewinding station, and because of that, it’s

Sister Company within the region transported their burned motors for rewinding or

repair. There are equipment that can only be found in the rewinding center such as Baker

AWA-IV Static motor Analyzer used for testing the insulation of the rewind motor and

oven where the motor insulation was left for the purpose of drying. This procedure was

called “baking”. The trainee was able to observe how to rewind burned motors. There

were initial steps before they can start rewinding such as (1.) taking data inside and out

which included the phase of motor inside and the terminals outside; and (2.) determining

the proper wire size of the motor to be rewind using American Standard Wire Gage for

non-ferrous metal (fig 11). The trainee was able to experience rewinding the burned

motors under the supervision of Sir Ceasar Nario Jr., the senior rewinder, and Sir Calvin

Torres, rewinder.

Specifically, trainee rewind the motor from SONEDCO. In doing this he was

guided by the rewinding personnel from cleaning of the burned motors to collecting the

needed data to start rewinding, and determining the proper wire size. The trainee cleaned

and stripped the wires from the motor and sprayed the insulation varnish to the stator (fig.

11), then the trainee begun cutting fish paper for winding insulation, which is a

vulcanized cellulose fiber frequently used for electrical insulation, commonly die cut and

used to fit in the slot of the motor. Lastly, the trainee begun on rewinding the wires with a
 20

specific gap of 1/10, 2/12, 3/14 and 4/16 (fig 12).

On the last day of duty, Sir Calvin Torres illustrated to the trainee how to connect

the terminals of a 12pin motor (fig 13).

Air-conditioning

The air-conditioning area was the one responsible for cleaning, repairing and

checking of ACU in the whole plant. The trainee started training at the air-conditioning

area during the off season repair. This provided the student trainee the chance to gain

more learnings since the student trainee can have a hands-on experience together with the

person in-charge was. The trainee was scheduled in this area for three days. Sir Jan Ryan

Casquite was the one who supervised the trainee. The trainee was able to observe the

proper wire connections and the different parts of an ACU. The trainee soldered the

copper tube (fig14) of the condenser where Freon that was converted to liquid flow to the

compressor. After that, Sir Jan Ryan Casquite tested the soldered copper tube using a

vacuum and soaked the cooper tube to the water with soap to test if there was any leakage

to the tube.

On the following day of duty, the trainee together with his co-trainee assisted in

cleaning and checking the conditions of the ACU in the admin department (fig15)

“servicing”. The trainee was also able to observe the proper ways of cleaning the ACU.

Instrumentation
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This area is under the supervision of Engr. Lyndy Oracion with the assistance of

electricians. Instrumentations is responsible in managing and maintaining company’s

equipment which were used to monitor and control the system, machinery and

equipment. On the first day of duty, the trainee was able to observe the electricians who

cleaned and checked the Variable Frequency Drive (VFD). Unfortunately, the

instrumentation was only permitted in cleaning and checking the controls, since repairs

were done only by the company who owned the controls. The trainee had also been

briefed and demonstrated about Differential Pressure Transmitter (DPT).

On the following days of his duty, the trainee accompanies the electrician

detaching pressure meter from the pipes for the purpose of calibration. The trainee was

able to observe how the instrumentation operated during off-season repair which is quite

different on milling season. All of the monitoring equipment was being checked and

cleaned by the instrumentation.

Other activities

The trainee was able to participate in the fire and earthquake evacuation

drill/simulation in coordination with the bureau of fire and Municipal Disaster Risk

Reduction Management Office (fig16). This was participated by the the personnel of

URC-SURE Tolong to promote awareness and prepare them for this kind of disaster.

Problems Met
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The plant was nearing the off-season repair. Hence, the experience and

knowledge of the trainee that he can gain is limited on the remaining days of his duty. He

wanted to gain more learnings as well as new experiences considering there were other

areas that fully operated during season repair. Also the student trainee was having a hard

time on familiarizing with the different machines, tools and areas that are being used

within the company.

Solution Made

The student trainee asked permission from the supervisor in charge and to their

OJT coordinator to allow him to continue his OJT in the off-season repair. The trainee

explained that he wanted to gain knowledge and experience from the OSR which can

enhance the student trainee’s learnings further. The student trainee was permitted by the

supervisor and OJT coordinator but the student trainee was required to make a letter that

indicated date the student trainee would leave and continue for his OJT. The student

trainee also provide a notebook inorder for him to list down the things that he is

unfamiliarized this help him remember the different machine and tool that is being used

within the company .

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CHAPTER V

GENERALIZATION

The internship or On-the-Job Training is a training in specific amount of time that

greatly helped the student trainee by exposing himself in the actual field of work which

allowed him to enhance his skills and apply the knowledge he learned. This also served

as a preparation for his future work.

Since the trainee was assigned in the five areas of the Electrical Department, he

was able to observe the different role and expertise of each department from motor

control, rewinding a motor, checking the conditions of motors, servicing of air-

conditioning unit, and checking the conditions of controls. Knowledge and attitude were

very important in handling these five areas.

The trainee was given several task such as designing a motor control and

rewinding a motor where he was challenged to learn more about motors and motor

controls and expanded his knowledge to guarantee the reliability and safety of the design.

During the OJT, the trainee realized the important of the training, exposing him to

the actual field of work and being able to observe its operations and apply the knowledge

and theories he had learned in the classroom.

 CHAPTER VI

DEFINITION OF TERMS

Case Study. An analysis of a particular case or situation and make it as a basis for

drawing conclusion in similar situation (Microsoft Encarta).

In this report, it refersto a case on emergency and communication alarm between

high grade centrifugal basket and sugar-warehouse at URC-SURE Tolong

Circuit Breaker. A device designed to open and close a circuit by nonautomatic means

and to open the circuit automatically on a predetermined overcurrent without damage to

itself when properly applied within its rating (Philippine Electrical Code 2017).

In this report, it refers to the equipment that was connected for the protection of

the alarm system.

Electrical Engineering. Engineering involving technical application of electricity. The

branch of engineering that studies the practical applications of electricity in science and

technology (Microsoft Encarta).

In this report, it refers to the course taken by the trainee.

Electric Motors. A group of devices used to convert mechanical energy into electrical

energy, by electromagnetic means (Microsoft Encarta).

In this report, it refers to the devises that needed to be supplied by electric power

to do a given task, and a device that is being rewind by the trainee.

Powerhouse Department. An electrical generating station (Microsoft Encarta).

 25

In this report, it refersto the section in URC-SURE that is responsible for the

control of all electrical related works.

Training. It is a process of teaching or learning a skill (Microsoft Encarta).

In this report, it refers to the actual application of learning that the trainee had

undergone for 240 hours by exposing him in the actual field.

 ACRONYMS

ACU - Air Conditioning Unit

ANSI - American National Standards Institute

ASEAN - Association of Southeast Asian Nation

BSEE - Bachelor of Science in Electrical Engineering

CPSU - Central Philippine State University

DPT - Differential Pressure Transmitter

HGCB - High Grade Centrifugal Basket

HTCI - Herminio Teves & Company Incorporation

HR - Human Resources

LSP - Low Steam Pressure

MOA - Memorandum of Agreement

MRC - Motor Rewinding Center

NTC - National Telecommunications Association

OIC - Officer in Charge

OJT - On-the-Job Training

OSH - Occupational Safety and Health

 27

PEC - Philippine Electrical Code

Pf - Power Factor

PMI - Preventive Maintenance Inspector

PPE - Personal Protective Equipment’s

RPD - Raw Production Department

rpm - revolutions per minute

SONEDCO - Southern Negros Development Corporation

TCD - Tons Cane per Day

TG - Turbine Generator

TIA - Telecommunication Industry Association

TSMC - Tolong Sugar Milling Company

URC - Universal Robina Corporation

URC-SURE - Universal Robina Corporation Sugar and Renewables

VD - Voltage Drop

VFD - Variable Frequency Drive

 CHAPTER VII

CASE STUDY

A Case Study on Communication System between

High Grade Centrifugal Basket Station and Sugar-warehouse

Background of the Study

Communication system plays a vital role in industrial sugar processing plant, they

provide proper communication that delivers important information on what is happening

inside the factory in order to have an efficient and continuous production.

The Universal Robina Corporation -Sugar and Renewables (URC-SURE) Tolong

is divided into different departments which are spearheaded by competent managers that

have the capability to manage and supervise the personnel assigned to them. The High-

Grade Centrifugal Basket (HGCB) Station can be located in the Raw Process Department

in which the high quality sugar is being dried, and then being transfered by the conveyor

to the sugar-warehouse where the finished product sugar is being stored, stocked and

packed. The present communication system being used by HGCB station and sugar-

warehouse is a Morse code (Figure 17 ans 17.1) in order for them to communicate. And

in case of emergency the HGCB station use the communication system to inform the

sugar warehouse on what is happening, whether they are having LSP, wet sugar, and stop

or resume the production. This communication codes (Figure 18) can sometimes be

misinterpreted and can result to miscommunication. During the training of the student
 29

trainee, the communication system was introduced to him by one of the shift

supervisor Engr. Matalino Cortez, the student trainee was able to observed how crucial it

was to have a proper communication between HGCB station and sugar-warehouse hence

effective communication played a vital role around the plant.

Case Proper

Effective communication is the ability to convey information to others effectively

and efficiently, communication helps facilitate the sharing of information between people

within a company for its commercial use. In order for the Sugar warehouse department

and High-Grade Centrifugal Basket station to communicate, a Morse code system was

being utilize by HGCB station and sugar-warehouse, the Morse code system is composed

by a buzzer, push button and connecting wires that is rated 2.0mm 2 THW . The Morse

code system is being used for sending and receiving of messages during production

process. The production process starts by the month of August until the month of May

every year during this span of time, the communication system “Morse code” was being

utilize and according to one of the personnel assigned to the sugar-warehouse there were

incidents where the sending personnel delivers incorrect codes and also when the

receiving personnel misunderstood the code that can result to misinformation, this

incidents especially occurs in the 12 am to 8 am shift. The miscommunication is mainly

caused by the personnel misinterpretation of the sender messages, and during the OJT of

the trainee he was given the opportunity to visit, roam and observed for not less than one

hour the operation of the factory especially the HGCB station and Sugar-warehouse

during the time he was assigned in the Powerhouse department, the student trainee was

able to witness one of the personnel in the HGCB station that is using the communication
 30

system is sending the messages repeatedly because the receiver cannot understand the

message of the sender. And according to one of the personnel assigned to the Sugar-

Warehouse there were incident, when they asked the HGCB station for a premium sugar

(wash sugar) but the HGCB station delivers brown sugar to the Sugar warehouse because

of the misinterpretation of the message.

This study focused in preventing miscommunication and the delay of messages

between the HGCB station and sugar warehouse.

Problem

Miscommunication between Sugar-warehouse and High-Grade Centrifugal Basket

station.

Objectives

1. To prevent miscommunication between the HGCB station and Sugar-

warehouse.

2. To improve the communication system of the HGCB station and Sugar-

Warehouse.

3. To design a communication system between HGCB and Sugar-warehouse.

Constraints

1. Unavailability of materials.

2. Distance of the HGCB Station to the Sugar-warehouse.

3. Unavailability of the personnel to check the communication system.

 31

Alternative Course of Action

1. Upgrading the communication system between HGCB station and Sugar-

Warehouse by adding lamps and labels on the present system.

2. Replace the existing communication system with a intercom system.

3. Providing radio phones to the assigned personnel in the HGCB station and

sugar-warehouse.

Analysis of Alternative Course of Action

1. Upgrading the communication system of the HGCB station and Sugar-

Warehouse.

Communication System is important in various industries in order to have continuous

operation. In order for the Sugar warehouse department and High-Grade Centrifugal

Basket station to communicate, the existing communication system (Figure 17 and 17.1)

a Morse code system was being utilize for sending and receiving mess ages. There are

instances where the sending personnel delivers incorrect codes that result to

misinformation. And when the receiving personnel misunderstood the code, they keep

repeating the message until receiver can understand the sender messages.

Due to alarm miscommunication, upgrading the communication system is highly

needed. The company should design a communication system that can deliver precise

messages and can be easily understand. It should be noticeable not only by sight but also
 32

by hearing, upgrading the communication system by adding lights, buzzer and label can

satisfy these requirements

The appropriate conductor size of the design is 2.0mm2 based from Article 3.10(

Conductors for general wiring) Table 3.10.2.6(B)(17) of the Philippine Electrical Code

(Table 4, Appendix J) and since the present wire that connects the “Morse Code”

communication system between the HGCB and Sugarwarehouse is 2.0mm2 THW then

the existing wires can still be used and for the circuit breaker (instanteneous type) rated

15AT based from Article 2.40 (Overcurrent Protection) Table 2.40.1.6(A) of PEC(Table

5, Appendix K) for the circuit protection. The electrical circuit (fig 19) and mechanical

design (fig 20) would serve as the guide for upgrading the system.

For upgrading the communication system, the company should purchase seven (7)

AC electromagnetic relay, sixteen (16) latching push button and fourteen (14) IEC

Ø22mm Integrated LED Pilot-Lights with a voltage rated 110V-240V AC. The total

estimated cost for upgrading the communication system is Php 5080 (Table 6). The

estimated date for the upgrading the communication system considering the delivery of

materials would be the next scheduled off-season repair or plant shutdown.

With this alternative, the “Morse Code” communication system (Figure 17 and

17.1) can be upgraded (fig 20) also the miscommunication can be avoided.
 33

2. Replace the communication system with a intercom system.

The current communication system is a Morse code system (Figure 17 and 17.1) to

deliver and send messages, but due to personnel misinterpretation it can cause

miscommunication and affect the operation of production. Replacing the communication

system with a telephone system is one of the solutions to prevent miscommunication.

An intercom system is a two-way communication electronic device that contains

circuitry for the purpose of transmitting and receiving audio transmissions. Wired

Intercom Systems is used when you run wires between locations, a wired system can give

you a little more privacy and eliminate possible interference from neighboring systems.

Full Duplex communication is what telephone uses, both parties on the call can speak at

the same time.

The wiring of most of the telephones are one or more twisted pairs of copper wire.

The most common type is the 4-strand (2 twisted pair). This consist of red and green

wires which make a pair, and yellow and black wires which make the other pair. One

telephone line needs only two wires, therefore a 4-strand wire can carry 2 seperate phone

lines. The copper cable is divided in different categories of Unshielded Twisted Pair

(UTP) currently the cable used for the telephone is CAT 3 based on (Table 7). The proper

size of wire for telephones in accordance to American National Standards Institute

(ANSI) and Telecommunication Industry Association, the standard specifically stated

that all cables in structured cabling should consist of four balanced twisted-pairs of 22

AWG to 26 AWG.

It is advantageous to replace the existing communication system with wired

 34

intercom system because the two station can send and receive clear and precise messages

that is needed to have a continuous and without delay operation. And also the telephone

should be place in an area where it cannot affect the working of the empolyee or cause

any disturbance to their working environment, so the student trainee come up with a

location layout for the telephone (Figure 22).

In materializing this action, the company need to purchase a 25 m of four (4)

balanced twisted-pairs of 22 AWG to 26 AWG cable and a two (2) way telephone

intercom the total estimated cost of this alternative is Php 2375 (Table 9).

With this alternative, miscommunication can be avoided and messages can be

delivered without any delay in a lower cost value.

3. Providing of radiophones for the assigned personnel between the two stations.

The current communication system of the Sugar-warehouse department and High-

Grade Centrifugal Basket Station is a Morse Code system. Which can be misinterpret and

can cause miscommunication and delayed the operation of the company. The trainee

proposes on providing a chargable radiophone for the assigned personnel in the High-

Grade Centrifugal Basket station and the Sugar-warehouse department.

Chargable radiophone is known for being less expensive but requires certain

frequency and can only transmit about 1 mile (1.6 km). Basically, by providing

radiophones for the assigned personnel on the two station they can communicate anytime

in-case of emergency. Also for the installation of a chargable radiophone it should be

 35

considered the charging area where it will not affect or disturbed the working

environment of the employees, so the student trainee proposed a location layout for the

charging station of the radiophone (Figure 23).

In materializing this alternative, the company must purchase two (2) radio phone,

one (1) for the personnel in-charge in the Sugar-warehouse and one (1) for the High-

Grade Centrifugal Basket Station the total estimated cost of this alternative is Php 2000

(Table 10).

With this alternative, miscommunication can be avoided and it has the advantage of

being easily carried and that the two station can communicate anytime during operation

but it has a disadvantage of delivering unclear messages.

Conclusion

After the student trainee had observed and studied the communication system, he

came to conclude that the main reason of the miscommunication of the Sugar-Warehouse

and HGCB station is due to the misinterpretation of messages of the personnel. The

trainee therefore concluded that to solve the problem, the company should purchase

material for upgrading the alarm, Since this alternative will utilize the existing materials

such as the buzzer and wires and can inform the employees directly for the sender

messeages

.
 36

Recommendation

After the student trainee analyze the current alarm system, the trainee proposed that

the alternative course of action 1 which stated, “Upgrading the communication system of

the HGCB station and Sugar-Warehouse” would be the most effective solution to the

miscommunication of the HGCB station and the Sugar- warehouse. With this, the

company could prevent miscommunication and provide appropriate preparations between

two stations to have a continuous flow of production.

Strategies of implementation

1. Propose the alternative course of actions to the management;

2. Once the proposal is approved, make the purchases;

3. Upon arrival of materials, conduct the installation;

4. Evaluate the performance.

5. Take corrective action if necessary.

6. Conduct maintenance.
 BIBLIOGRAPHY

Handbook of Intercom Systems Engineering, first edition

Obiedo, K. G. (2017). A Comprehensive Report on the On-the-Job Training at URC-

SURE. A report required for the Degree of Bachelor of Science in Electrical
Engineering (BSEE), Central Philippine State University (CPSU), Kabankalan
City, Negros Occidental.

PHILIPPINE ELECTRICAL CODE (PEC),2017 Part

Policarpo, M. E. (2019). A Comprehensive Report on the On-the-Job Training at (PPA-

PMO) A report required for the Degree of Bachelor of Science in Electrical
Engineering (BSEE), Central Philippine State University (CPSU), Kabankalan
City, Negros Occidental.
FIGURES
 39

Figure 1: Steam Turbine Generators

Figure 2. Diesel Generator “Caterpillar”.

 40

Figure 3: Switchboard of TG1

Figure 3.1: Switchboard of TG2 and TG3.

 41

Figure 4: The trainee performed connecting the three motor control

Figure 5: Direct online starting method

 42

Figure 6: Forward reverse starting method

Figure 7: Wye delta starting method

 43

Figure 8: Steam distribution

Figure 9: Student Trainee toured around the plant

 44

Figure10: Motor control design for 45 kW motor.

Figure 11: American Standard Wire Gage for non-ferrous metal

 45

Figure 12: The trainee rewinding

Figure13: The trainee connecting the terminals of a 12 pin motor.

 46

Figure 14: The trainee soldering the copper tube.

Figure 15: The trainee servicing ACU in the admin department.

 47

Figure 16: The trainee participates in fire and earthquake evacuation drill/simulation.

Figure17: Existing communication system.

 48

Figure 17.1: Existing communication system

Figure 18: Bell code (Morse type)

 49

Figure 19: Circuit of the proposed upgrade of the communication system.

 50

Figure 20: Mechanical design

Figure 20a: Mechanical design

 51

Figure 21: Dimension and guide for the fabrication of the alarm.

Figure 22: Location layout for the installation of Intercom.

52
 53

Figure 23: Location layout for the charging station of radiophone.

TABLES
 54

TABLE 1. TELEMECANIQUE Manufacturer Rating for Magnetic Contactor.

Manufacturer Reference Ratings

LC1 D09 4 kW, 9A

LC1 D12 7.5 kW, 12 A

LC1 D18 9 kW, 18 A

LC1 D25 11 kW, 25 A

LC1 D32 15 kW, 32 A

LC1 D40 22 kW, 40 A

LC1 D50 30 kW, 50 A

LC1 D65 37 kW, 65 A

LC1 D80 45 kW, 80 A

LC1 F115 59 kW, 115 A

LC1 F150 80 kW, 150 A

LC1 F185 100 kW, 185 A

LC1 F265 140 kW, 265 A

LC1 F330 200 kW, 330 A

 55

TABLE 2. TELEMECANIQUE Manufacturer Rating for Overload Relay.

Manufacturer Reference

LR2 D1306 1A – 1.6A

LR2 D1307 1.6A - 2.5A
LR2 D1308 2.5A - 4A
LR2 D1310 4A - 6A
LR2 D1312 5.5A - 8A
LR2 D1316 9A - 13A
LR2 D1321 12A - 18A
LR2 D1322 17A - 25A
LR2 D2353 23A – 32A
LR2 D3355 30A - 40A
LR2 D3357 37A - 50A
LR2 D3359 48A - 65A
LR2 D3361 55A - 70A
LR2 D3363 63A - 80A
LR2 F5369 100A - 160A
LR2 F5371 125A - 220A

TABLE 3. Motor Controller Guide at 440V Power Supply.

kW HP Full Load Minimum Circuit Contactor OLR
Current (A) wire size Breaker
(75oC) (A)
0.4 0.5 1.1 14 3 LC1 D09 LR2 D1306
0.6 0.75 1.6 14 3 LC1 D09 LR2 D1306
0.8 1 2.1 14 3 LC1 D09 LR2 D1307
1.1 1.5 3 14 7 LC1 D09 LR2 D1308
1.5 2 3.4 14 7 LC1 D09 LR2 D1308
2.3 3 4.8 14 7 LC1 D09 LR2 D1310
3.8 5 7.6 14 15 LC1 D09 LR2 D1312
5.6 7.5 11 14 15 LC1 D12 LR2 D1316
7.5 10 14 14 30 LC1 D18 LR2 D1321
11.3 15 21 10 30 LC1 D25 LR2 D1322
15.0 20 27 10 50 LC1 D32 LR2 D2353
18.8 25 34 8 50 LC1 D38 LR2 D3355
 56

22.5 30 40 8 100 LC1 D40 LR2 D3357

30.0 40 52 6 100 LC1 D50 LR2 D3359
37.5 50 65 4 100 LC1 D65 LR2 D3361
45.0 60 77 3 250 LC1 D80 LR2 D3363
56.3 75 96 1 250 LC1 F115 LR2 F5369
75.0 100 124 2/0 250 LC1 F150 LR2 F5369
93.8 125 156 3/0 250 LC1 F185 LR2 F5371
112.5 150 180 4/0 250 LC1 F265 LR2 F5371
150.0 200 240 250 400 LC1 F330 LR2 F5375
 57

TABLE 4. Allowable Ampacities of Single-Insulated Conductors Rated Up to and

Including 2000 Volts in Free Air, Based on Ambient Temperature of 30oC*.
Temperature Rating of Conductor

60oC 75oC 90oC

Types Types
TW,UF RHW,
THHW, Types TBS, SA, SIS, FEP,
THW, FEPB, MI, RHH, RHW-2,
THWN, THHN, THHW, THW-2,
XHHW, THWN-2, USE-2, XHH,
USE, XHHW, XHHW -2,ZW-2
Conductor ZW
Size mm2
COPPER
2.0(1.6)* 25 30 35
3.5(2.0)* 30 35 40
5.5(2.6)* 40 50 55
8.0(3.2)* 55 65 75
14 80 100 110
22 105 130 145
30 125 150 165
38 145 175 195
50 180 210 235
60 200 235 265
80 245 290 325
100 285 340 380
125 335 400 445
150 375 445 505
175 410 495 560
200 440 530 590
250 510 620 685
325 600 720 800
375 645 775 875
400 660 795 890
500 755 905 1020
 58

TABLE 5 Computation of Loads.

CKT LOADS VA V I
Indicator Lamp 86.94 230 0.378 A
(14-230V,27mA)
1 Round Bell Buzzer 9.2 230 0.04 A
(200mm, 230 V)
(2- 230V, 20mA)
TOTAL - 120.175 230 0.5225 A

TABLE 5.1. Standard Ampere Ratings for Circuit Breakers

Standard Ampere Ratings

15 20 25
30 35 40
45 50 60
70 80 90
100 110 125
150 175 200
225 250 300
350 400 450
500 600 700
800 1000 1200
1600 2000 2500
3000 4000 5000
6000

TABLE 5.2. Alternating-Current Resistance and Reactance

 59

TABLE 6. Estimated cost for the innovation of the alarm system.

MATERIALS QUANTITY UNIT PRICE TOTAL

CONNECTING WIRES
( 2.0mm2 THWN ) EXISTING
AC RELAY 7 120/pc 840
CIRCUIT BREAKER (15 AT) 1 350/pc 350
PLANE SHEET (8ft x 3ft x 1 180/roll 180
0.02in)
RIVETS 1 170/box 170
PUSH BUTTON 16 138/10pcs 280
SIGNAL ALARM INDICATOR 14 45/pcs 630
LIGHT
TERMINAL BLOCK 2 290/pc 580
STEEL CONDUIT 21 50/m 1050
LABOR - 2396 1000
BUZZER EXISTING
TOTAL PRICE - - 5080
 60

Category Type Spectral Length LAN Applications Notes

B/W
Cat3 UTP 16MHz 100m 10Base-T, 4Mbps Now
mainly use
for
telephone
cable
Cat4 UTP 20MHz 100m 16Mbps Rarely seen
Cat5 UTP 100MHz 100m 100Base-Tx,ATM, Common
CDDI for current
LANs
Cat5e UTP 100MHz 100m 1000Base-T Common
for current
LANs
Cat6 UTP 250MHz 100m Emerging
Table 7. Specifications for Cat3, Cat4, Cat5, Cat5e, and Cat6 Cables based on Tel-Data
Communiations.
 61

Table 8. Cost Computation of two (2) way telephone intercom

Materials Quantity Unit price Total

2-way telephone 2 1000/pc 2000

CAT3 cable 25m 15/m 375

Total Price - - 2375
 62

Table 9. Cost Computation of the radiophone

MATERIALS QUANTITY UNIT PRICE TOTAL
Radio phone 2 1000/pc 2000
Total price - - 2000
APPENDICES
 65

APPENDIX A. Communication Letter

\
66
 67

APPENDIX B: Medical Certificate

 68

APPENDIX C: Memorandum of Agreement

69
 70

APPENDIX D. Parent Consent

 71

APPENDIX E. Calendar of Activities

Date Activities
April 8, 2019 - Attended Occupational Environmental Health and

Safety (OEHS) orientation.

- Electrical Department Orientation.

- Plant tour and visit.

April 9, 2019 - Assigned on Powerhouse.

- Observed the operation.

- Toured from water treatment to milling department.

- Observed the operation of turbine generators.

- Observed the different connections of motor control.

April 10, 2019 - Toured in the Motor Rewinding Center and ACU

repair shop.

- Observed in rewinding of motors.

- Observed in repairing of ACU.

- Observed in Ampere reading with Sir Villo

- Discussed about the history of company and problems

the company encountered.

April 11, 2019 - Observed replacing of fluorescent lamp.

- Practiced connecting wye-delta, Direct Online and

 72

reverse forward.

- Accompanied Sir Villo in checking the circuit breaker.

April 12, 2019 - Observed in ampere reading in the electrical

department.

- Checked of the fluorescent in the chemist laboratory.

- Toured in the whole URC plant.

April 13, 2019 - Toured in the milling department with Sir Villo.

- Introduced to the different kind of motor.

- Took nameplate and specifications of motor.

- Observed the installation of new ACU in the

powerhouse.
April 15, 2019 - Practiced in Connecting Wye-delta connection.

- Observed in withdrawing equipment in the warehouse.

- Visit the MRC.

- Helped in cleaning the slot of the motor.

- Observed in testing of AWA.

- Engr. Matalino toured the trainee in the Mill 1 to Mill

4 and RPD.

- Discussed the principles of VFD and PLC.

 73

April 16, 2019 - Assisted in covering the motor together with Sir Villo.

- Discussed the operation of caterpillar (GenSet).

- Discussed the organizational chart.

April 17, 2019 - Observed the current of each phase of motor controller

- Visited the MRC and discussed about the types of

motor and different techniques for rewinding of motor.

- Engr. Matalino Cortez discuss the principle of turbine

generator.
April 22, 2019 - Discussed why transmission line had high voltage.

- Engr. Matalino toured the trainee and introduce the

capacitor banks.

- Toured to the warehouse, and introduce the basic

codes of Electrical Materials.

- Asked to design basic motor controller with rating and

codes.
April 23, 2019 - Discussed about the design of the motor control.

- Observed the change of power factor.

- Discussed the power triangle.

April 24, 2019 - Half day

- Visited the sugar warehouse with Sir Electona to

 74

check the breakers.

April 29, 2019 - Roam around the plant and observe the process of

milling.
April 30, 2019 - Ampere reading with Sir Eumage.

- Did trainee observed the different motor control that

was being read.

May 1, 2019 - First day on Maintenance

- Observed in repairing of CCTV in the bagasse area.

- Engr. Tubongbanua introduced the different types of

motors that were being monitored in the Preventive

Maintenance.
May 2, 2019 - Milling was suspended.

- Assigned at the Motor Rewinding Center

- Observed rewinding of motors.

- Toured to the water treatment.

- Started cleaning the motor for rewinding.

May 3, 2019 - Observed taking of data and information for rewinding

of motors.

- Started cleaning the slot of motor for rewinding.

- Stripped the burned wires.

May 6, 2019 - Cleaned the slots of burned motors.
 75

- Sprayed electrical varnish to the burned motors.

- Fitted and cut fish paper for the slots of the motor.
May 7, 2019 - Prepared for rewinding the motors.

- Fitted the fish paper inside the slots.

May 8, 2019 - Prepared papers for leave and continuation for the off

season repair.

- Accompanied Engr. Coloyan for taking specifications

of ACU.

- Identified the conductor size for the rewinding of

motors by using American Wire Gage.

May 9, 2019 - Identified the proper spacing for each wire.

- Fitted of wires on each slot.

- Continued rewinding.

- Instructed and briefed the connection of terminals for

12 pin motor.
May 10, 2019 - Processed and Signed papers for the leave.
June 03 2019 - Observed the testing of motor that has been rewind

using AWA ( electric motor analyzer )

- Observeed the disassembling of motor in the mills.

- Helped cleaning the power house for the repairs.

June 04 2019 - 1st day in air-conditioning repair-shop.
 76

Started on cleaning the copper tube.

Cleaning, Cutting and Expanding.

- Started soldering the copper tube.

- Tested the copper tube if there is a leakage using the

vacuum.

- Toured to the sugar warehouse and check the alarm

system and how the sugar being packed.

- Toured to the HGCB checking if how the alarm

works.
June 06 2019 - Visited the HR office to inform the HR secretary for

our certificate of completion.

- Asked question about the connection of (capacitor of

fan), (capacitor of compressor), thermostat,

compressor, main switch and compressor.

- Reassembled the ACU connection.

- ACU testing.

- Visited the powerhouse since they begin on

disassembling the turbine generator.

- Sir leonard obabana introduced us about the tg1

 77

(6pins,excitation rotor, and rectifier )

- Visited the mills because the instrumentation

department checked the connection of VFD and PLC.

- Discussed us the function of VFD and PLC.

- Engr. Cortez discussed to us the illustration of the

rectifier connection for the excitation of the rotor.

- Went to the boiler and check the source of the steam

and how it is distributed to the mills and Turbine

Generator.
June 07 2019 - Helped in servicing together with Sir Casqutie in the

admin

- URC-SURE Tolong joined in conducting earthquake

drill and fire drill together with the firefighting team.

From 1 pm to 4 pm.
June 08 2019 - First day in instrumentation

- discussed us the Differential Pressure Transmitter

( DPT

- Observed in servicing of PLC and VFD.

 78

- Engr. Oracion toured the trainees to pans and

evaporator.

- Helped putting filter on the control panels

June 10 2019 - Assisted on getting the DPT in the boiler department.

- Toured and explained to the different way to monitor

your steam and water in the boiler.

- Explored inside of the boiler

June 11 2019 - Visited the control room of the boiler since the

employees are servicing the PLC and VFD in the

control room.

- Observed the cleaning of evaporators.

June 13 2019 - Observing the function of DPT.

Electro-pneumatic rotary positioner. And Actuator.

-
 79

APPENDIX F. Daily Time Record

80
 81

APPENDIX G. Certificate of Completion

 82

APPENDIX H. Police Clearance

 83

APPENDIX I. Computation for 45kW Motor Control Direct Online.

Pf= 0.75

E= 440

P=EI (√ 3) (pf)

45kW = (440) (I) (√ 3) (0.75)

I= 78.73 A.

Therefore:

a.) Circuit breaker is 250 AT since the current of DOL is inrush.

b.) Main Contactor is LCDID80 (45kW, 80 A)

c.) Overload Relay is LR2 D3363 (63 – 80A)

d.) Motor rating 45 kW and I= 78.73

 84

APPENDIX J: Calculation of Voltage Drop for Proper Wire Sizing.

Voltage Drop formula

VD= kDI√ ¿2+X2)

For single phase k=2

The distance of the two station is approximately equal to 20m. For allowance add five
meters. Total of 25m.

From table 5

The total current of the alarm system is 0.5225

From table 5.2

Resistance of 2.0mm2 in a steel conduit conductor is 3.1 per 305m.

Reactance of 2.0mm2 conductor in a steel conduit is 0.073 per 305m.

Substitution of data to the formula

VD = kDI√ ¿2+X2)

VD = (2) (0.5225)¿ ¿2 + (0.073)2] *(25/305)

VD = 0.2656 V.
 85

APPENDIX K: Design Analysis of the Alarm System

CKT # 1:
INDICATOR LAMPS
(14-230V, 27mA)

I = 0.378 A

ROUND BELL BUZZER (200mm, 230 V)

(2- 230V, 20mA)

I = 0.04 A
IT = 0.5225 A

USE: 15 AT CB
2-2.0 mm THW
in ½ inch Ø RSC
 86

APPENDIX L: Training Plan for OJT

 87

APPENDIX M: Performance Rating

88
89
90
91
92
93
94
95
96
97
98
99
100