INDUSTRIAL TRAINING

AT
TENAGA NASIONAL BERHAD (SHAH ALAM)
DISTRIBUTION NETWORK TNB
PERSIARAN DAMAI SEKSYEN 11
BY

DEPARTMENT OF
ENGINEERING
UNIVERSITI TENAGA NASIONAL

START DATE:
END DATE:

DEPARTMENT OF ENGINEERING

Chapter Title Page

Abbreviation 4
Abstract 5
Acknowledgement 6
1.1 Company name 7
1 1.2 Company profile 7
1.3 Company vision 7
1.4 Company mission 8

1
 1.5 TNB shared values 8
1.6 TNB business 9
1.7 Core business 9
1.8 Non-core business 9
1.9 Management Service 9
1.10 Training and development 9
1.11 Operation and maintenance 9
1.12 Rationale of logo 10
1.13 Symbol 10
1.14 Corporate name 10
1.15 Corporate Colours 11
1.16 Organization Structure 11
2.1 TNB Generation 13
2 2.2 TNB Transmission 14
2.3TNB Distribution 15
2.3A Pencawang masuk utama 16
2.3B Pencawang pembahagian utama 17
2.3C Stesen suis utama 17
2.3D Pencawang elektrik 18
3.1 Schedule 19
3 3.2 Safety 20
3.3 Unit operation & maintenance 21
3.3A Field crew 22
3.3B SAVR 23
3.3C Substation unit 25
3.3D Cable unit 26
3.3D(i) Cable fault detection 29
3.3D(ii) Cable joint 30
3.4 Unit network planning 40
3.4A Type of supply 40
3.4B Consumers standby supply 41
3.4C Alternative source of supply 42
3.4D Provision of temporary supply 42
3.4E Single tenant premises 43
3.4F Multi tenanted premises 43
3.5 Unit metering 44
3.5A Service 44

4.1 Discussion 49
4 4.2 Conclussion 49
4.3 Reference 50

2
ABBREVIATION / DEFINITION

3
CBM Condition Based Maintenance
CEB Central Electricity Board
CPP Cadangan Perancangan Projek (Project Planning Proposal)
CSP Cas Sambungan Perpasangan (Connection Charge Payment)
CSR Corporate Social Responsibility
CUF Centralized Utility Facility
DPMS Distribution Project Management System
ERMS Enterprise Resource Management System
Foremen Senior Technician
FP Feeder Pillar
GI Galvanized Iron Pipe
HDD Horizontal Directional Drilling
HDPE High Density Poly Ethylene
ILSAS Integrated Learning Solution
IPP Independent Power Producer
IR Insulation Resistance
K&S Kendalian dan Selenggara
LF Load Factor
LPC Large Power Consumer
MD Maximum Demand
MSL Minimum Service Level
MSVR Memgukuhkan Sistem Voltan Tinggi (Medium Voltage System Upgrade)
MSVT Memgukuhkan Sistem Voltan Rendah (Low Voltage System Upgrade)
NEB National Electricity Board
NOP Naturally Off Point
OPC Ordinary Power Consumer
OW1 Operasi Wilayah 1 (Operating Region 1)
OW2 Operasi Wilayah 2 (Operation Region 2)
PD Partial Discharge
PE Pencawang Elektrik (Distribution Substation)
PECU Photoelectric Control Unit
PF Power Factor
PIDAR Polarization Index & Dielectric Absorption Ratio
PILC Paper Insulated Lead Cable
PM Preventive Maintenance
PMU Pencawang Masuk Utama (Transmission Main Intake Substation)
PPU Pencawang Pembahagian Utama (Primary Distribution Substation)
PVC Poly-Vinyl Chloride
REMACO TNB Repair & Maintenance Sdn. Bhd.
RM Routine Maintenance

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 RMU Ring Main Unit
S/S Stesen Suis (Switching Station)
SSU Stesen Suis Utama (Primary Switching Station)
TNB Tenaga Nasional Berhad
TNBD TNB Distribution Sdn. Bhd.
TNBR TNB Research Sdn. Bhd.
UPJ Unit Pemasangan Jangka
VCB Vacuum Circuit Breaker
XLPE Cross Link Poly-Ethenyl Cable

ABSTRACT
The industrial training report is done as per requirement set by University academic

regulation for the completion of industrial training and to present the knowledge gained in the

3 months we are in the training. As students of Diploma in Electrical Engineering, it is

compulsory to take Industrial Training as one of its course Requirement. It is 12 weeks

program of explosion to a company which aid students in sharpening soft skills, developing a

sense of working environment, , improving our knowledge and capability between the

students, employee and colleagues.

The company that I have joined for my internship is Tenaga Nasional Berhad, or better

known as TNB. TNB is the largest power utility company in Malaysia and South East Asia,

with MYR 100+ billion worth of assets. Tenaga Nasional Berhad is divided to several main

divisions, mainly TNB Generation, TNB Transmission and finally TNB Distribution;which

serves the end user customers.

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 ACKNOWLEDGEMENT

My heartfelt gratitude goes College of Engineering, especially to Madam Redia Binti Mohd

Redzuwan as the coordinator of Industrial Training for a smooth coordination during the

three month period. Besides that, gratitude to Sir Muhammad Hanif Bin Abdul Karim as my

visiting lecturer for making his time to get updated with my progress during internship.

I would like to thank the following for their respective professionalism and contribution to
the program:
 Puan Nor'ain Ismail, Pembantu Tadbir Kanan
 Mr. Zulkafrie Bin Abdul Ghaffar, Technician (LV Operation, Repair & Recovery)
 Mr. Abdul Aziz, Supervisor cabel (11kV)
 Mr. Zaizuri Bin Sazali, Technician (Maintenance Executor HT)
 Cik Nur Herleen Baizura Binti Kamaruddin, Engineer (Project Implementation)
 Puan Farah Binti Ismail, Engineer (Supply Planning 11kV)
 Puan Nurhamizah Binti Mansoor, Engineer Device Operation (Metering Unit)

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 CHAPTER 1
INTRODUCTION TO THE COMPANY

1.1 COMPANY NAME

The name of the company is Tenaga Nasional Berhad or better known as TNB. There are

several sub companies under TNB and the subcompany I am interning at the TNB

Distribution Networking, Selangor.

1.2 COMPANY PROFILE

Tenaga Nasional Berhad (TNB) is the largest electricity utility in Malaysia and a leading

utility company in Asia. Listed on the Main Board of Bursa Malaysia with almost RM100+

billion in assets, the Company’s more than 50,000 employees serve an estimated 15+ million

customers in Peninsular Malaysia, Sabah and Labuan. TNB has been keeping the Lights on in

Malaysia ever since it was set up as the Central Electricity Board in 1949, powering national

development via the provision of reliable and efficient electricity.

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TNB’s core businesses are in the generation, transmission and distribution of electricity. In

Peninsular Malaysia, the Company supplies households and industry with electricity

generated from six thermal stations and three major hydroelectric schemes. It also manages

and operates the National Grid which links TNB power stations and IPPs to the distribution

network. The grid is connected to Thailand’s transmission system in the north and

Singapore’s transmission system in the south. In East Malaysia, TNB has an 80% equity in

Sabah Electricity Sdn. Bhd. (SESB), which manages the Sabah Grid.

Other than its core business, TNB has diversified into the manufacture of transformers, high

voltage switchgears and cables; the provision of professional consultancy services; and

architectural, civil, electrical engineering works and services, repair and maintenance. The

Company also engages in research and development, property development and management

services. Tapping into opportunities available overseas, TNB is making inroads into

emerging markets, focusing on the Asia-Pacific, Middle East and North Africa regions.

In 2005, the Company embarked on a 20-Year Strategic Plan with the ultimate objective of

transforming into a world-class player by the year 2025. To support this vision, TNB invests

significantly in the continuous professional development of its employees through structured

programmes. There is also renewed emphasis on sustainability, both of the organisation and

of the Malaysian environment. The Strategic Plan entails greater focus on green initiatives

such as the development of renewable sources of fuel, and more effective demand side

management via energy efficiency, thus complementing the Government’s carbon reduction

agenda.

1.3 COMPANY VISION

"To Be Among the Leading Corporations in Energy and Related Businesses Globally"

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1.4 COMPANY MISSION

"We Are Committed to Excellence in Our Products and Services"

1.5 TNB Shared Values

There are four important shared values that all the staff in TNB must follow :

1. Integrity

2. Business Excellence

3. Customer Focus

4. Caring

1.6 TNB Business

Core business, non-core business, managing service, training and development, operation and

maintenance.

1.7 Core Business

o Generation

o Transmission

o Distribution

1.8 Non Core Business

o Subsidiaries

o Associates/ Investment Companies

o Trust Foundations

1.9 Management Service

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Associates/ Investment Companies

1.10 Training and Development

ILSAS, our world-class Centre of Excellence in training of power utility competency and

related services

1.11 Operation and Maintenance

TNB Remaco, our independent subsidiary for repair and maintenance services of power plant

equipments

1.12 Rationale of Logo

Figure 1.12 Logo TNB

The Corporate Logo for Tenaga Nasional Berhad (TNB) symbolizes the Company's

continuing goal to provide services to the national needs with renewed emphasis on our

dynamic future.

1.13 Symbol

The Corporate Identity for TNB is based on an easily recognised application of electricity –

the light bulb. The form of the bulb is highly stylised, giving a sense of vitality and of the

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future. It is a clean, efficient design and formed almost entirely by one single line, resolving

inside the bulb shape with a lightning symbol, dramatising TNB's electrical energy function.

The shape of the bulb suggests the form of a "T" – representing "tenaga" (energy).

1.14 Corporate Name

Figure 1.9.1 Corporate Name

The name of Tenaga Nasional Berhad concisely summarises the Company's role. It is

depicted in the Corporate Logo with a clean, sophisticated typeface that projects TNB's

exciting future.

The lettering is italicised to represent the dynamic role that TNB will play in the nation's

progress. The typeface is bold, to depict the Company's inherent strength, confidence and

reliability.

1.15 Corporate Colours

The logo symbol is in a brilliant red to symbolise energy. It is a most impactful colour

connoting excitement and confidence. The corporate title is in a cool, solid blue – giving a

sense of corporate strength and dignity, a perfect complement to the red logo. Red and blue

together also reflect the colours of the national flag – appropriate for a vital national service.

1.16 Organization Structure

Below depicts the organizational structure of Tenaga Nasional Berhad

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 Figure. Organisational structure

Figure. Business Organisational Structure

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 CHAPTER 2

TNB ELECTRICAL POWER SYSTEM

2.1 TNB GENERATION

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Generation station is the main source in TNB for generate electricity. The Generation

division owns and operates thermal assets and hydroelectric generation schemes in Peninsular

Malaysia and it has a generation capacity of 11,296 MW.

TNB GENERATION POWER STATIONS

 HYDROPOWERED POWER PLANTS

 COAL FIRED POWER PLANTS

 OIL FIRED POWER PLANTS

2.2 TNB TRANSMISSION

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TNB has transmission including the National Grid which is energized at 132, 275 and

500 kilovolt (kV), with its tallest electricity pylon in Malaysia and the National Grid is linked

15
via 132 kV HVAC and 300 kV HVDC interconnection to Thailand and 230 kV cables to

Singapore. More than 430+ transmission substations in the Peninsular are linked together by

approximately 11,000 km of transmission lines operating at 132, 275 and 500 kilovolts (kV).

The 500 kV transmission system is the single largest transmission system to be ever

developed in Malaysia. Begun in 1995, Phase 1 involved the design and construction of the

500kV overhead transmission lines from Gurun, Kedah in the North along the west coast

to Kapar, in the central region and from Pasir Gudang to Yong Peng in the south of

Peninsular Malaysia.

The total distance covered for the 500 kV transmission lines is 522 km and the 275 kV

portion is 73 km. Of the lines constructed, only the Bukit Tarek to Kapar sections had been

energized at 500 kV. The remaining lines are presently energized at 275 kV. Later, in order to

cater for the additional power transmission requirements from the

2,100 megawatt (MW) Manjung Power Station, the 500 kV system was extended from Bukit

Tarek to Air Tawar and from Air Tawar to Manjung Power Station. In 2006, the 500 kV lines

between Bukit Batu and Tanjung Bin were commissioned to carry the power generated by the

2,100 MW Tanjung Bin Power Station.

2.3 TNB DISTRIBUTION

The Distribution division conducts the distribution network operations and electricity retail

operations of TNB. The division plans, constructs, operates, performs repairs and

maintenance and manages the assets of the 33 kV, 22 kV, 11 kV, 6.6 kV and 415/240 volt in

the Peninsular Malaysia distribution network.  To conduct its electricity retailing business, it

operates a network of state and area offices to purchase electricity from embedded generators,

market and sell electricity, connect new supply, provide counter services, collect revenues,

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operate call management centers, provide supply restoration services, and implements

customer and government relationships

The substations under the governance of TNB Distribution is the PMU-Pencawang Masuk

Utama , PPU- Pencawang Pembahagian Utama, SSU-Stesen Suis Utama, PE-Pencawang

Eletrik and feeder pillars.

2.3A PENCAWANG MASUK UTAMA (TRANSMISSION MAIN INTAKE)

Transmission Main Intake is the interconnection point of 132kV or 275kV to the distribution

network. The standard voltage transformations provided at the PMU are as follows:-

- 275/132kV

- 132/33kV

- 132/11kV

2.3B PENCAWANG PEMBAHAGIAN UTAMA

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Main Distribution Sub-station is normally applicable to 33kV for interconnecting 33kV

networks with 11kV networks. It provides capacity injection into 11kV network through a

standardized transformation of 33/11kV.

2.3C STESEN SUIS UTAMA

SSU at 33kV, 22kV and 11 kV are established to serve the following function:-

1. To supply a dedicated bulk consumer (33kV, 22kV, 11 kV)

2. To provide bulk capacity injection or transfer from a PMU/PPU to a load center for further

localized distribution.

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2.3D PENCAWANG ELEKTRIK

Distribution sub-stations are capacity injection points from 11 kV, 22kV and sometimes

33kV systems to the low voltage network (415V, 240V). Typical capacity ratings are

1000kVA, 750kVA, 500kVA and 300kVA.

Conventional substation designs are of indoor type (equipment housed in a permanent

building) and out-door type (ground-mounted or pole-mounted). Standardized M & E design

of 11/. 433kV sub-station is available at TNB offices. Compact substation (11 /. 415kV) has

limited application and is to be strictly applied in selective situations under the following

circumstances:-

 System reinforcement projects for highly built-up areas where substation land is

difficult to acquire.

 Any request to use compact substation for dedicated supply to a single or limited

group of low voltage consumers is subject to TNB approval in accordance to site

constraints situation, and to be considered as ‘special feature design schemes’.

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 Standalone Substation

CHAPTER 3
WORK EXPERIENCE BASED ON DEPARTMENTS

3.1 SCHEDULE

I, Trainee arrive at TNB Shah Alam, trainee report himself to the Human Resource Group

level one under the Administrator Department. Trainee start training on the 18 th February

2019 till the 10th May 2019, a total of 13 weeks.

Trainee is given a schedule to be followed, in TNB Shah Alam rotation approach is given to

all trainee. This approach is taken into consideration for trainee to be well exposed to the

structure of Tenaga Nasional Berhad and obtain new experience and knowledge as well.

Below is the training schedule during this internship period.

Schedule of Trainee

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 Date /Week Department
18/02/2019 - 15/03/2019 Unit Operation & Maintenance
18/03/2019 - 05/04/2019 Unit Asset Development
08/04/2019 - 23/04/2019 Unit Network Planning
24/04/2019 - 10/05/2019 Unit Metering

3.2 SAFETY

Before trainee going to site, it is very important for trainee to know about safety in TNB.

Safety and health is taken into high priority in TNB. Every TNB executive and technicians

should adhere to the safety principles highlighted by the government and TNB. Safety

Practice is emphasize to minimize accident during operation and to ensure a safe environment

for the worker as well as public .Exercising safety

Precautio in TNB include;

o Wearing the Personal Protective Equipment

Every technical operators in TNB is required to be equipped with the Personal

Protective Equipments. These equipments include;

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 Safety Shoes Safety Vest

Safety Helmet

3.3 Unit Operation & Maintenance

Trainee report to Puan Nur Atiqah (Assistance Engineer) which give a brief introduction as

well as trainee is introduced to the members of the department. Jurutera Kanan K&S (Senior

Engineer) is responsible in coordinating the maintenance and repair operation of each

installation in TNB. To ease the maintenance management, the Operation and Maintenance is

divided into four smaller divisions, which are the Field Crew, SAVR (Sesalur Atas Voltan

Rendah), Cable/Locate Unit, and Substation Unit. All of the operation and documentation in

these units are assisted by the office clerks.

3.3A Field Crew:

COMPLAINS

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There are few mediums to received issued complain by public, customer and etc. The

mediums are mentioned below :-

 TNB Outage Management System (TOMS)

 SMIT

 Street Furniture (SF)

 Electric Eyes

 Patrolling (Rondaan)

1) 2)

1) TNB Outage AutomatioManagement System (TOMS)

2) Mobile Field Force Automation

TNB will dispatch the work to PDA contractor through Mobile Field Force Automation

(MFFA).The contractor will attend to the repair needed till it is completed. Duration of the

work involving street lighting should not exceed more than 12 hours. Complains on street

lighting may be unable to function as usual due to certain factors for example sensor fault,

contactor fault, LV cable fault, Street lighting cable fault, defendant on lantern and etc where

it is address by TNB to be fix. Besides that if the problem is caused by the panel of MBSA ,

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TNB will leave it to MBSA to perform the fixation .Figure below depict the workflow of

complains involving street lighting

Workflow on the progression of complains

3.3B SAVR (Sesalur Atas Voltan Rendah)

SAVR (Sesalur Atas Voltan Rendah) is a state of work being conducted on low voltage with

procedures, safety measures and the type of tools which is allowed by TNB's system. It

provides voltage to users through overhead method and also savr installing lv pole. As a

trainee I’m observing them doing technical work and help them a bit. Hence trainee are

expose to this two responsibility and was able to grasp on knowledge related to street

lighting. Sometime new application of electric supply of street lighting is handle by street

lighting unit. It is under Lembaran Kerja-Kerja Kecil (LKKK).

COMPONENT IN STREET LIGHTING

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 Pole - Concrete (mainly handle by TNB) and Street Lighting Steel Panel (PBT- in

Shah Alam

 Street lighting wire

 Lantern- consist lamp bulb and electromagnetic control gears such as the ignitor and

ballast. There is a capacitor for power factor correction. Lantern will be prewired only

requiring connection of electrical power supply cables to terminal block and the

continuity conductor to earthing terminal.

 Bracket- accessory in street lighting assembly.

 Photoelectric Control Unit (PECU)

 Meter and etc.

Street Lighting Layout

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Installing new lamp Installing new pole

3.3C SUBSTATION UNIT

Substation is one of TNB asset that should be well taken care and observed and observed at

Shah Alam. Shah Alam has many type of substation in the zone as shown in Figure below.

The type of substation to be build depends on the space provided by the developer.While in

substation unit, all we have to do is cleaning the substation, mostly cleaning battery charger,

checking meter and making sure the every device in substation is working well like EFI

(Earth Fault Indicator). The substation consists of feeder pillar, transformer, and switch gear

and position of each item depends on the type of substation:

Outdoor Substation H-Pole Substation

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 Indoor Substation Compact Substation

Cleaning battery charger Checking meter is reading well

3.3D CABLES UNIT

As the name suggests, Cable maintenance unit deals with medium voltage underground cable

maintenance. Medium voltage underground cables are cables that carries 33kV load from

PMU to PPU and henceforth. This unit also deals with breakdowns and repair works as

cables are the main lifeline in power transmission.

Trainee were exposed to different types of cable with sizes and their current carrying

capacity. Cables that exist in TNB power system is Cross Link Poly-Ethylene (XLPE) or

Paper Insulated Lead Cable (PILC), it’s a co-joint of both of this cables in the national grid

of Malaysia Power System. However the use of PILC is therefore any faulty PILC Cables are

to be replaced. Cables are mediums that connect the electricity supply between the main

intakes, substations, feeder pillars, and the consumer meters. All of the Medium Voltage

cables use the Delta Configuration (Δ). These Medium Voltage cables are connected to the

Step-Down Transformers of Delta-Wye Configuration (Δ-Υ), resulting the low voltage cables

27
to be bear by the Wye Configuration (Y). In general, cables at TNB is categorized into two

which into a two categories, which are underground cable and overhead cable. Underground

Cables refer to the cables that are buried under the surface of the ground. Laying a cable

underground is done through a few methods, which are open trench (At the road bank, under

a vehicle road). Trainee was brought to the Yard to show the cable and its size so that they

may be familiar with the cables.

There two types of joining cable that are:

Termination joint Straight through joint

Below are table indicating its conductor ratings, conductors fuse, cables ratings, transformer

and cable fuse ratings according to its types

i) Conductor

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Table 8.2.1 PVC
Size Rating Al (A) Rating Cu (Al) Max Fuse Al Max Fuse
(A) (A)
(25mm) 90 110 60 80
(35mm) 120 140 80 100
(70mm) 180 230 125 160
7/173 (100mm) 250 160

Table 8.2.2 Aeriel Bundled Cable (ABC)

Size Rating (A) Max Fuse (A)

1 x 16 + 25 80 50
3 x 16 + 25 80 50
3 x 95 + 70 190 125
3 x 185 +120 300 200

Table 8.2.3 Bare Aluminium

Size Al Rating (A) Max Fuse (A)
3/132 120 80
7/122 (50mm) 170 100
7/173 (100mm) 280 160

i) Cables /Transformer
Table 8.2.4 XLPE
Size 11Kv Low Voltage
Rating (A) Rating (A)
25 110
70 190
120 250
185 320
200 400

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 95 210
150 280
240 350
500 550

Table 8.2.5 PILC

Size 11 kV Low Voltage
Rating (A) Rating (A)
25 80 90
70 140 160
120 200 230
185 250 290
300 330 380

Table 8.2.6 Low Voltage cables

Size PILC XLPE
Max Fuse (A) Max Fuse (A)
25 60 75
70 100 100
120 125 160
185 200 200
300 250 250

Table 8.2.6 Transformer

Size 11kV 22 kV 33 kV
HT Fuse (A) HT Fuse (A) HT Fuse (A)
50 5 5 2
100 10 5 5
300 20 15 10

30
 500 50 25 20
750 75 40 30
1000 90 50 40

3.3D (1) CABLE FAULT DETECTION

Cable fault are fault that occurs at joints or on the cable itself. This type of faults required that

section of cable to be dug up and replaced. Joint fault requires new joints to be done. Medium

Voltage Cable joints dominant failure modes identified by TNB Distribution Division are

localized defect caused by assembly error, localized defect caused by material defect and

insulation ageing. For terminations additional dominant failure modes

identified by TNB Distribution Division are localized defect caused by environmental stresse

s, localized defect caused by insulator tracking and insulation ageing due to water

penetration. Most of the above failure modes progress slowly to deteriorate the condition of

the joints and terminations over time.

3.3D (2) CABLE JOINT

Pre-moulded with outer resin & tape straight through joint for 3 core XLPE cables

1. Overlap the cables to be jointed by 300mm and mark the reference line at the centre of the
overlap. Clean the cables on both side of jointing position.

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 U
2. CABLE PREPERATIONS (150 – 240 mm2)
Prepare the cables as shown in drawing above. Remove outer sheath, armour and inner sheath
to the dimensions given in drawing.

3. Align the cores to match the phasing. Cut the cores off at reference line. Remove the

copper tape screen & semicon (semi-conductive insulation screen), to the dimension from the

reference line as shown in drawing above. If required smoothen the XLPE insulation.

Remove insulation to the dimension ‘L’. Clean the cores with solvent.

4. On longer side apply stress grading mastic around the core at semi-con terminating point

so that mastic overlaps the semi-con and XLPE insulation by 5mm. Wrap one layer PVC tape

around conductors on the longer side as shown in the drawing above.

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5. Apply paste inside the push on device and slide over the conductors and butt against the

insulation. Apply assembling paste over semicon, XLPE insulation and push on device on

longer core side. Apply some extra paste at the end of push on device over the insulation as

shown in drawing above.

6. Apply assembling paste inside the joint body thoroughly. Insert joint body over each core

on longer side and position so that the inner end of joint body remains 20mm away from the

copper tape screen end. Ensure that all the required joint body has been slide on the cores as

shown above.

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7. Flair the tinned copper wire stocking sleeve and insert one over the each longer core and

push towards crutch as much as possible. Remove the push on device and PVC tape from the

conductor.

8. Insert the connector over conductors. Crimp the connectors with suitable tool. File off

burrs. Abrade and clean the connectors. Clean and degrease the exposed conductor, XLPE

insulation and connector.

9. Measure the distance between ends of insulation. Make a mark over the connectors at

HALF of this measured distance. Measure and note the distance ‘D’ from the centre mark of

connector up to the end of copper tape of smaller coreside.

10a. IN CASE OF DEEP INDENTTYPE CRIMPING USED:

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Fill the gap between the connector and insulation with semi-conductive tape to achieve a

smooth conical shape. On short side apply stress grading mastic around the core at semi-con

terminating point so that mastic overlaps the semi-con and XLPE insulation by 5mm.

10b. IN CASE OF HEXAGONAL OR NOVA TOOL TYPE CRIMPING USED:

Starting from the smaller core side fill the gap between the connector and insulation with

semi-conductive tape and continue apply one layer 50% overlap over the connector and finish

at the end near longer core side to achieve a smooth profile. On short side apply stress

grading mastic around the core at semi-con terminating point so that mastic overlaps the

semi-con and XLPE insulation by 5mm.

11. Apply assembling paste over connector and the XLPE insulation over one core.

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12. Push back the joint body and position it centrally over the connector. Check and adjust

the centre mark of joint body at measured and noted distance ‘D’ from the end of copper tape

of smaller core side. Similarly slide the joint body of other cores following step 11 & 12.

13. Cut the black mastic in two half and apply it around the core butting against the end of

joint body on both sides. Overlap the mastic over the joint body ends by 10 to 15mm.

14. Postion the tinned copper wire stocking sleeve centrally over the joint and pull it both

ends over the copper tape screen to make it tight fit over the joint. The wire stocking sleeve

should overlap the copper tape screen by 50mm on either side. Connect the copper wire

stocking sleeve over the metal tape with roll springs on either side.

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15. Cover the roll springs with PVC tape to hold the roll springs on either side.

16. Apply one layer of polythene tape with slight overlap around the wire stocking.

17. Press the cores to bring them together. Abrade and clean the XLPE cable outer sheath for

about 150mm. Leaving 150mm from the ends of outer sheath apply black mastic around the

outer sheath on either side.

18. Place the cable spacer net centrally over the joint and wrap it around the joint. Pull both

the ends together and join them with the sufficient number of cable ties. Tighten the braid

over the joint by pulling from both the end. Apply black mastic tape at the ends of cable

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spacer net. Place one pouring gate at the ends on either side and one pouring gate at the

centre of cable spacer net.

19. Starting from one side outer sheath of cable apply sealing tape with half overlap and

slight tension around the black mastic, cable net, poring gates and continue up the outer

sheath of other side cable.

20. Starting from one side outer sheath of cable apply reinforced tape with half overlap and

slight tension around the black mastic , cable net, pouring gates and continue up the outer

sheath of other side cable.

21. Mixing instruction for polyurethane resin and hardener:

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The compound must not be mixed until the joint covering has been finally completed and is

ready for filling. Cover hands with plastic gloves. Tear off outer bag from the small nick at

one end. Remove the inner bag from outer bag. Thoroughly knead the resin side to dispense

any settlement. Remove the separator. Empty the hardener into the resin compartment

squeezing and rolling up the hardener compartment to ensure as much hardener as possible is

included in the mix. Mix the resin and hardener by tipping the mixture vigorously from end

to end for approximately 2 minutes. Squeeze the compound away from one another corner of

the bag and cut off the corner to form a pouring hole. Mixing and pouring should be

completed in less than 10 minutes. Start pouring the compound first pour through the gates

placed over the both the ends of joint and when flow of compound slows down then pour

from the centre gate. Pour compound steadily into the joint through pouring gates of it to

level of 3mm below the top of turrent.

Note: Each pack of compound needs to be mixed and poured immediately following the

previous pack.

22. Make a slanting cut 5 to 10mm wide up to the sealing tape at the centre of two gates on

both sides to allow if any air to pass out, and wait till resin starts oozing out from the cuts

without air bubbles coming out. Ensure that knife cut is not very sallow and only up to

the tape. Pour some more resin in all gates to top up.

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23. When out flowing resin has no air bubbles, close and seal the cut with sealing tape. Also

check level of resin in pouring gates and pour some more resin if required.

24. Wait 30 minutes for compound to harden. Clean the upper edge pf all the pouring gates

and fix the cover over the gate. Apply black mastic around the collar of cover and seal it with

sealing tape. Similarly fix the other two covers over the balance pouring gates.

25. Joint is completenow, ensure that resin is harden before applying mechanical strain or

refiling the joint pit.

A few picture of doing a cable joint:

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3.4 Unit Network Planning

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Planning department is the third department I was posted to during the training period. The

planning department is responsible in planning out the entire TNB system in the region they

are in control. Application for new power supply to new housing or industrial projects are

forwarded to this department for consideration and feasibility. Puan Farah is one of the

engineer in Planning Department. She teach me a valuable lesson of Planning Guidelines and

Distribution Code for TNB system planning. This department handles a lot of guidelines and

law in creating the perfect and stable system for the applicants before approval is given.

Many meetings will be held before a project approval is given.

3.4A Types of Supply

Supply Application Based on Load

All new applications and upgrade of supply requirement can be classified into two (2) types

of supply applications.

1) Supply Application For Load Up To 100 KVA

 Supply from existing supply mains or establishment of new supply system (subject

to system capability)

 Submission of applications to TNB by Electrical Contractor registered with the

Energy Commission

2) Supply Application For Load Exceeding 100 KVA

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  Supply from existing supply mains or establishment of new supply system.

 Submission of applications to TNB by Electrical Consultant Engineer registered with

the Board of Engineers Malaysia.

Note: Establishment of new supply system may require the construction of a new sub

station/substations and its related ancillaries.

Supply Application for Streetlight can be categorize as follows based on TNB’s prevailing

policies and guidelines:

 Application made by the local authority/government department

 Application by developer.

 Application by individual.

For any supply involving co-generating, a separate licence need to be obtained from the

relevant governing authority.

3.4B Consumers Standby Supply

Standby generator(s) may be used by the applicant at their premises, subject to compliance

with the relevant laws. The generators shall remain a separate system from TNB distribution

system and the applicant shall declare to TNB on the safe installation of the generator(s).

This may be used in place of TNB’s supply source through a suitable, approved changeover

facility. The Energy Commission and other relevant authorities govern the usage of

generators and standby supply.

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3.4C Alternative Source of Supply

A large consumer may require an alternative source of supply. TNB will provide such

alternative supply at an additional cost fully borne by the consumer.

3.4D Provision Of Temporary Supply

Application for a Temporary Supply means the electricity supply required is for a

nonpermanent installation intended for a limited time. When a consumer is requesting for a

permanent supply, but a planned supply source is not available at that point of time and

temporary connection from another source of supply is constructed, the case is not considered

as a Temporary Supply.

Examples of Temporary Supply are, but not limited to, festivals or exhibition sites, circuses

and construction sites (inclusive of the worker's quarters).

Tariff for Temporary Supply shall be determined based on the usage of the Temporary

Supply premise. For example, Tariff A is for the worker's quarters on construction site,

Tariff B, C1 or C2 for construction site, festivals, exhibitions or circuses. A surcharge of

33% of the total bill, shall be charged monthly through out the Temporary Supply term.

3.4E Single Tenant Premises

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 If the supply is for a single tenant only then the entire supply will be metered at the

applicant’s incoming switchboard. The consumption will be charged at the appropriate tariff

rates.

3.4F Multi Tenanted Premises

(a) Commercial Premises (excluding shoplots)

Multi tenanted commercial premises except shop lots shall be given bulk supply. It shall be

the responsibility of the owner / developer of the multi tenanted commercial premises to

obtain independent distribution license from Energy Commission.

(b) Domestic Premises

Multi tenanted domestic premises, the owner / developer / Joint Management Committee

shall have the option of taking supply via bulk supply or individual supply to landlord and

tenants. If on bulk supply it shall be the responsibility of the owner / developer of the multi

tenanted commercial premises to obtain independent distribution license from Energy

Commission.

(c) Shop Lots

Shop lots shall be given individual supply.

The design, installation and operating of such electrical systems shall comply with

requirements of all the relevant authorities including the Energy Commission’s and TNB’s.

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3.5 Unit metering

Trainee was introduced that LPC is divided into three type of customer which are low power

consumer, medium power consumer and high power consumer. Low power consumers are

customer which requires less than 1kV supply to be able to perform their daily work

activities. Medium power consumers are customer which requires a supply of electric of

11kV or 33kV whereas High Power Consumer are customer which requires 132kv direct

from the transmission line. In the Shah Alam zone quantity of one customer whom takes up

132 kV which is Nippon Electric, Japanese based marble company. Mostly trainee follow

technician install OPC due to the technican that installing LPC have no space for me to

follow in their car.

Ordinary Power Consumer focus on the smaller group of customer where it focus on

customer who need one phase supply or three phase supply. Where one phase require a 30

Amps while three phase need a supply of 60 Amps or 100 Amps.

3.5A SERVICE

The Service Unit is known as the ‘mini’ Planning and Construction Division, as it small scale

projects with the charge of less than RM100 000 and less than 100A current consumption

both LPC and OPC are handle by this unit.

The Service Unit handles various TNB related constructions made by the applicants,

involving;

New/Temporary electric supply application

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Electric supply application under this unit only involves small scale procedures, such as

tapping supply from the existing service cable, etc. The process may require the installation

of new electric pole, junction box, etc. Temporary electric supply application normally

involves applicants for construction sites etc. This supply will expire after duration of time,

and will be disconnected.

Upgrading single phase meter to three phase meter or Current Transformer

Consumer that needs a demand of 60 Amps, a meter upgrading is necessary that is a 3 phase

meter. But TNB will not handle the rewiring process of the project. The customer needs to

employ the electrical contractor to perform the rewiring, and TNB will only change the meter

once the rewiring is complete and accurate according to TNB’s specifications.Any demand

above 100 Amp should have a Current Transfomer and a meter to be able to meet the

requirement.

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Unit Pemasangan Jangka (UPJ)

UPJ manages its operation through the clauses of instructions called the ‘Work Order Type’.

These instructions help to organize and keep track on the tasks and its completion. Among

the work order types commonly exercised in UPJ are as follow:

WORK ORDER TYPE DEFINITION

11 Install new meter For new premise or reconnecting old user’s
premise

21 Take initial reading & give supply Reconnecting supply after being cut

22 Take final reading & cut supply Cutting supply due to overdue bill

l30 Replace damaged meter Due to meter faultiness after being tested

32 Schedule replacement A wave of replacement for old meters

33 Meter replacement Due to wrong meter registration

40 Remove meter from vacant premise Upon request from customer

41 Remove meter from disconnect premise Upon request from customer

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 92 Investigation (Meter Related) Non-technical investigation

99 Miscellaneous Involving any operation that is not listed

among the existing work order types such
as relocating meter due to visibility
complaints from the meter reader, or testing
meter due to complaints from customer

11 Install new meter

92 Investigation (Meter Related)

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CHAPTER 4

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 DISCUSSION AND CONCLUSION

4.1 Discussion
Industrial Training program by UNITEN is very effective program and useful in order to

expose students to an actual working environment. It is a platform to mold student and allow

them to be opinionated and practice their problem solving skills. TNB Shah Alam had

allowed me to observed engineering theory in reality for example transformer is to Step up

and Step down Voltage where Electric Machinery was observed in detailed. Also being in

TNB has taught me on how to be a good and diplomatic person as well as an engineer. We

have to be diplomatic with our staffs so they will not feel pressured or feel hatred towards

myself if I were to ask them to do a job. Safety is also paramount in TNB as we deal with

deadly voltages that can kill. Therefore safety must be observed at all time to avoid such

disaster.

4.2 Conclusion

During three month of training in TNB Shah Alam I have learned so much knowledge that I

never known before. I only learned theoretical knowledge in Universiti Tenaga Nasional,

having industrial training course really helps to balance my theoretical knowledge and

practical knowledge. I have been taught so much things during my industrial training period

and I am really glad to have a good supervisor that is showing and teaching me at TNB Shah

Alam which improve my knowledge.

Other than that, I have gained so much working experiences. I have been exposed to an actual

working experience by following technician going to site in a hot day and learn how it is feel

working atmosphere. I believe that practical knowledge and theoretical knowledge is not very

important when it comes to working together. There are many kinds of skills that a person

needed in order to create a better environment in the company.

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In conclusion, Industrial Training has allowed me as an individual to grow and arise to

different type of situation. It is a great course to prepare oneself to become a well trained and

competent engineer in mere future.

4.3 Reference

 Buku Panduan Piawai Baru Rekabentuk Pencawang Elektrik (Jenis

Bangunan),Bahagian Pembahagian, TNB

 Substation Design Manual, TNB Distribution

 Electricity Supply Handbook, TNB

 DISTRIBUTION SYSTEM PLANNING:PRINCIPLES ,CRITERIA

&METHODS,ISSUES & WAY FORWARD, Halim Osman,General Manager,Asset

Management,TNB Distribution- UNITEN ARSEPE 2008

 XLPE Insulated Cables, Tenaga Cable Industries. http://www.tcisb.com.my/XLPE

%20Insulated%20Cables.pdf

 UNITEN Industrial Training Program Guidelines

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