Project Spotlight: Safe & Precise Alternator Dismantling

In the demanding environment of the palm oil industry, equipment reliability is the backbone of production. KH Venture recently successfully completed a critical maintenance operation: the dismantling and removal of a main alternator from its steam turbine prime mover.

This project required not only mechanical expertise but also strict adherence to safety protocols to navigate the unique hazards of the mill environment.

1. Safety First: The "Zero Energy" Mandate

For KH Venture, the safety of our workforce is non-negotiable. Before a single tool was lifted, our team initiated a strict electrical isolation protocol.

Our guiding principle for this phase was simple but vital: "Make sure all the current is no current."

The team performed a complete Lockout/Tagout (LOTO) procedure on the main circuit breaker. However, we did not rely on the switchgear indicators alone. Using calibrated voltage detectors, our competent persons physically verified the terminals to ensure the equipment was "dead." Only after confirming absolute zero voltage across all phases did we issue the permit to proceed.

2. Pre-Work Assessment: The IR Test

Before mechanically decoupling the unit, KH Venture performed a mandatory health check on the alternator windings via an Insulation Resistance (IR) test.

We disconnected the AVR to protect the sensitive electronics and applied the insulation tester to the windings. We weren't looking for complex calculations or deep analysis at this stage; we simply "check the IR test" to get a clear confirmation of the winding condition.

By recording these resistance values prior to dismantling, we established a baseline "health report" for the client. This ensures that the condition of the alternator is documented before it is moved or transported for servicing.

3. Execution via Strict SOP

Dismantling heavy machinery in a palm oil mill requires navigating heat, humidity, and the presence of conductive palm fibre dust. KH Venture followed a rigorous Standard Operating Procedure (SOP) to ensure the asset remained protected throughout the process:

• Cable Management: All power and control cables were carefully disconnected and clearly labeled to ensure seamless re-installation later.
• Mechanical Precision: The coupling separation and bolt removal were executed with precision to prevent strain on the turbine shaft.
• Asset Protection: Immediately upon lifting, all open cable boxes and air vents were sealed. This critical SOP step prevents oil mist and fibre dust from entering the internal windings during the move.