S. VIGNAESWARANB . E n g ( M O N A S H , A U S T R A L I A )

M S C . B I S ( K E E L E , U N I T E D K I N G D O M )

M I E ( A u s t ) E A N O : 3 3 9 3 7 8 6

Chartered Application Presentation(Brisbane EA office, 15th November 2012, 1.00 pm)

This presentation is based maximally on the Brisbane experience, and has been supplemented with Malaysian experience where it

is unavoidable.

G E N E R A L I N T R O D U C T I O N C O M P L I A N C E T O E A R E Q U I R E M E N T S M A C R O V I E W O F P R O J E C T S D O N E K E Y V E R I F I C AT I O N A R E A S

- C A B L E S I Z I N G S O F T WA R E - C O N V E Y O R B E LT D E S I G N

- A U S T R A L I A N S TA N D A R D S S U S TA I N A B I L I T Y E N G I N E E R I N G E T H I C S

Agenda for today’s presentation

My electrical (electrical automation) engineering experience.

Points to note:

Varied projects

International

Multi-market segment

Large scale projects

Multiple roles & scope

22 years of experience

Submission reference: item A- K Compliance reference: C1.1 – C1.3

Project Location Category Details Role

University campus Saudi Arabia Building Services AUD 2.2 billion Consultant

Coal Seam Gas India Oil & Gas upstream AUD 10 million ++ EPM / Designer

Power plant Malaysia Utility AUD 700,000 ++ DPM /Site Engineer

Renewable / Energy audit

Malaysia Utility AUD $20,000 Design Consultant

Wilson Transformer Victoria, Australia OEM Transformer design Designer / Trainee

ELCOM Sydney, Australia Quasi-Govt Power station EIA Designer / Trainee

Bitumen plant Malaysia Private sector AUD 100 million ++ EPM / Designer

100 ++ tenders (international)

Malaysia All segments Up to AUD 130 million Designer / Estimator

Distribution SCADA Malaysia Utility Automation $100 million ++ Specialist vendor

Mineral Mining plant Brisbane, Australia Mining AUD 100 million ++ E&I Designer

currently Malaysia Utility On-going Utility designer

Design Site work Management others0

2010 years 6 years5 years 1 years

Shared values My practices to date

Ethical behavior

Competent performance

Innovative practices

Equality of opportunity

Social justices

Sustainable development

I have indirectly fulfilled this with my signed CV and by the comments in the ethical slides

I have published 3 international and numerous career related papers and have fulfilled the CPD requirements in 1 year

This will be elaborated later in the standards, conveyor design and cable sizing slides

I have worked with employers from all background and under varied circumstances in Saudi, India and elsewhere, like EWB.

I have supported and made a difference by undertaking work in developing and needed areas like CSG and renewable energy

This will be elaborated later under the sustainability slide

What I have done to maximize my chances of being a chartered engineer ….

The learning process is as important as the knowledge which is acquired

Compliance reference: C1.1 – C1.3

Projects that I have been involved (in Australia)

MAK – copper/molybdenum project E&I specifications

Velta – Arc furnace plant electrical (green field) design

Ernest Henry, Mt. Isa Magnetite plant– E&I expansion / upgrade (brown field) design

Covered areas: Greenfield, Brownfield, Standards, Design and Engineering Office Practices

Compliance reference: C2.1 – C2.6, C3.1 – C3.6, E1B.1 – E1B.8, E4B.1 – E4B.4

MAK project

Three areas of concern:

COMPREHENSIBLE list of applicable standards for CB, Tx, cables etc?

Can the common and specific standards be referenced separately?

Can I sign the specification documentation prior to being a chartered?

080-I610-0001_0 Project Specification for Process Control Systems.pdf AS / NZS 3000 Electrical installations AS ISO 15745 Industrial Automation Systems and Integration - Open Systems

Application Integration Framework AS ISO 18876 Industrial Automation Systems and Integration - Integration of Industrial

Data for Exchange, Access and Sharing AS 60529 Degrees of protection provided by enclosures (IP Code) AS 61000, Electromagnetic compatibility (EMC) AS 61508, Functional Safety of Electrical/Electronic/Programmable Electronic

Safety Related Systems AS IEC 61131, Programmable Controllers AS IEC 61511, Functional Safety - Safety Instrumented Systems for the Process

Industry Sector

080-I610-0002_0 Project Specification for Nucleonic Instruments.pdf AS 2381 (All parts) – Electrical equipment for explosive gas atmospheres –

Selection, installation and maintenance AS 3000 Electrical installations AS 60529 Degrees of protection provided by enclosures (IP Code)

080-I610-0003_2 Project Specification for Control Valves.pdf AS/NZS 3000 Electrical installations AS/NZS 60079 Electrical apparatus for explosive gas atmospheres AS/NZS 60529 Degrees of protection provided by enclosures (IP code) AS/NZS 61000 Electromagnetic compatibility (EMC) AS/NZS 61241 Electrical apparatus for use in the presence of combustible dust IEC 60534 Industrial-process control valves ISA 5.1 Instrument Symbols and Identification ISA S75.01.01 Flow Equations for Sizing Control Valves

Compliance reference: C2.1, C2.4, E1B.8Specifications referring Australian standards

Velta arc furnace design

Detail of electrical design logistics;

● reliability of source

● redundancy for S/S

● cable routing logistics

● power harmonics and dips

Greenfield design

Gaining confidence in the transferred knowledge is as important, if not more than the transfer of knowledge itself = technology absorption

Compliance reference: C1.4

Xstrata Mt. Isa Magnetite plant capacity expansion project

Client standards

Existing design

guidelines

Inconsistency check

Australian standards

highlighted to Client

Client approval

Internal design process

Revised guidelines

Applicable standards

New drawings

Client approval

Operations & maintenance

Component failure

Power failure

Automation failure

Contingency

consideration

Existing drawing

Electrical (conveyor)

design process

Cable design process

Compliance reference: C2.1 – C2.6Brownfield design

Electrical design software challenges( standardize electrical design activities)

Electrical cable

design

PowerPac Pro

Software issues (slides)

Sample test

calculations

PowerCAD design

software

Constraint in time and resources

Costly to purchase / no

vendor support

No guidelines in its design usage

No flexibility / traceability in its

use

Use demo version for initial

design

Use Excel spreadshee

t

AS 3000 guidelines

Verify the output

Finalize cable size

calculation

Format cable design

presentation in Excel

Submit for Client

approval

Field side verification

Compliance reference: C3.1 – C3.6Electrical design office administration

PowerPac software issues -

1

An upstream breaker of 16 Amps was chosen with a specific let through energy.

Cable size : 25 mm2

Compliance reference: E4B.1 – E4B.4

PowerPac software issues -

2

A larger upstream breaker was chosen with its corresponding let through energy

Cable size : 35 mm2

Compliance reference: E4B.1 – E4B.4

PowerPac software issues -

3

A much larger breaker size with a comparatively smaller let through energy

Cable size : 25 mm2

Do we accept this on the basis that a RELIABLE 100% fast trip will be required to limit the let through energy?

Why do cable short circuit calculations? Worst case = costly cable size

Does the software establish the boundary of design accuracy? kV?

Compliance reference: E4B.1 – E4B.4

Does this software address copper clad aluminum (CCA) cables?

Does the standards address copper clad aluminum (CCA) cables?

CONVEYOR BELT PULL WIRE

SWITCH DESIGN

This active logic circuit carries continuous current at 110Vac which is energy inefficient.

The contacts can weld under continuous current at 110Vac

The pullwire logic can be implemented by ‘negative logic’ circuits as in the Oil & Gas field.

Compliance reference: E4B.1 – E4B.4

Pullwire

Australian standards

This compliance flowchart refers to electronic switches while the prior one refers to electro-mechanical switches.

Standards referenced determine application or visa versa?

Need to search compliance at Clause level to introduce cross segment good practices.

Compliance reference: E4B.1 – E4B.4

Do we introduce SIL and redundancy of power supply?

Sustainability Non-sustainability

Using a cable one size larger to cater for future loads

Placing plant equipment and building with a contiguous future growth space

Using electrical design software with systematic design approaches

Considering environmental issues and co-ordinating with the other disciplines for a holistic design approach

Energy saving approaches as in the conveyor design issues

Sizing the cable exactly for the current load capacity

Placing plant equipment randomly and/or with no usable space

Doing design calculations on paper without traceability and/or verifiability.

Consider only E&I issues and set design responsibility battery limits

Accept current practices and not consider possible improvements or enhancements

Sustainability - The need to fulfill current needs without adversely impacting future options or needs.

To have the same privileges or close to the same benefits in the future as a result of our present action Compliance reference: E1B.1 – E1B.4

Engineering ethicsThis can be summarized into 2 key words;

Judgment

Judgment is making an informed decision as what is contextually right and wrong. (why)

Transparency

Transparency involves disclosure of the whole issue over the period in concern, to all the stakeholders.

Stakeholders involves all those affect by the issue now and in the future.

Disclosure involves discretion (or it is whistle blowing)

Ethically wrong but legally right circumstances in engineering practices …

Charging Client for research work while doing Client’s project

Not highlighting possible operational and maintenance impact of design decisions

Not requesting for additional resources to carry out a comprehensive plant design

Not finding international jobs when the local jobs are limited or to gain exposure

Not changing specialization or moving out of comfort zone when the circumstances require to do so.

Compliance reference: C3.1 – C3.6

“ The world needs more smart, intelligent and tech savvy engineers and less of cunning, devious and legally savvy practitioners ”

Chartered Application Presentation(Brisbane EA office, 15th November 2012, 1.00 pm)

The End

Activities Outcomes

I have been a professional in my field My EA submission is based on 1 year in

Australia I had limited opportunities to fully comply I have adopted continuous learning process I am sharing my knowledge with my peers I need to share my knowledge with my

juniors in a recognized manner I need to legally contribute to the

Australian engineering arena I intend to work and live in Australia

permanently

I have had no adversities throughout my career The focus was on my Australian experience only A full project life cycle was not possible due to

current global economic circumstances Learning flow chart highlighted in the slides EA project management presentation and

international papers presented I have 22 years of validated international

engineering experiences to share CPEng is required to practice in QLD and a

valued asset elsewhere in Australia CPEng is a necessary recognition to provide

designer services, increase job and career opportunities

Why I Should be a Chartered Engineer

Completed CPD and Stage I requirements Currently working in Malaysia as an Electrical Utility Designer