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Faculty of Engineering List of Experiment / Activity Department: Electrical and Computer Engineering S/N Location/Project 1 Location: Location: WS2-05-10 Electrical Machines and Drives Lab Project : Highly Efficient Digitally Controlled AC-DC Converter with PFC Capability And Output Voltage Regulation [RS : Lim Shu Fan] [PI: A/P Ashwin M. Khambadkone] Last updated: 29 Feb 2008 Lab Supervisor Work Experiment / Activities (Routine / Non-Routine) Building and testing of AC-DC converter A/P SK Panda Priority Normal Target Date for Assessment Ready to assessment Faculty of Engineering Activity Sequence List - Activity or Experiment-Based Risk Assessment Experiment / Activity Steps Department: ECE No. Experiment / Activity 1 Building and testing of AC-DC converter Location: WS2-05-10 Laboratory: Electrical Machines and Drives Lab Workable Sequence/Task Solder components to build AC-DC converter Connect the converter to the AC and DC power supplies Turn on the power supplies to the converter Switching load for generating transients for functional verification Faculty of Engineering Activity or Experiment-Based Risk Assessment Form Department: ECE Name of Experiment/Activity: Building and testing of AC-DC converter Location: WS2-05-10 Name of Person in-charge: Lim Shu Fan Last Review Date: 29 June 2009 Next Review Date: 29 June 2012 1. Hazard Identification No. 1 Task Solder Hazards Mishandling Possible Consequences Burns is allowed to do build AC-DC soldering Toxic lung problem Smoke absorber S L R 1 1 1 2 1 2 1 1 1 1 2 2 Use the lead free solder 2 Connect the Over current / short converter to the circuit Burns External On / OFF switch, circuit AC and DC power breakers trip supplies 3 Turn on the power supplies to the converter Over Current Over heating Burns Limit the maximum current in the power supply control panel To avoid large current transients in DC power Last updated: 29 Feb 2008 A/P Ashwin M. Khambadkone 2. Risk Evaluation & Control Existing Risk Control (if any) Only trained person components to converter Name of PI: Additional / New Risk Control S L R Action By Deadline Faculty of Engineering supplies, increase the voltage slowly to the desired value Use external fan to dissipate the heat in the semiconductor devices Current leakage Burns Ensure all earths 1 2 2 1 2 2 and terminals are good, RCCB trips 4 Switching load for Over Current Burns Limit the maximum generating current in the transients for power supply functional control panel verification Note: Please refer to the attached SOP for details Conducted by: (Name, designation) Lim Shu Fan (RS), A/P Ashwin M. Khambadkone Signature: Date: Approved by: (Name, designation) A/P Ashwin M. Khambadkone (Project supervisor) Signature: 29 Sept 2009 Date: 29 Sept 2009 Risk Assessment Matrix Likelihood Severity Minor Moderate Major Remote (1) Occasional (2) Frequent (3) 1 2 3 2 4 6 3 6 9 (1) (2) (3) Severity Categories Level Human (Impact to Physical Being) Biological Impact Environmental Damage Property Damage (S$) (1) Minor No Injury or light injury requiring only first aid treatment (MC < 4 days MC) Any injury/ill health leading to ≥ 4 days MC or ≥ 1 day hospitalisation or leads to temporary disability May not cause human disease, if does, the disease is unlikely to spread to the community and there is usually effective prophylaxis or treatment available; Reversible Up to $5,000 Can cause severe human disease, not ordinarily spread by casual contact from one individual to another; it may spread to the community, but there is usually effective prophylaxis or treatment available Reversible but takes years $5,001 to $50,000 Fatality, permanent Disability or life threatening disease Can cause lethal human disease, may be readily transmitted from one individual to another, or from animal to human or vice-versa directly or indirectly, or casual contact, it may spread to the community; usually no effective prophylaxis or treatment available Irreversible More than $50,000 (2) Moderate (3) Major Likelihood Categories Level (1) Remote (2) Possible (3) Frequent Events Frequency Undesired event which may occur but unlikely, once in 5 years Undesired event which is probable, once in a year Undesired event which probably occur in most circumstances, once or more in a month Risk Level and Acceptability Criteria Risk Score Risk Level Acceptability of Risk <3 Low Risk Acceptable 3–4 >4 Medium Risk High Risk Last updated: 29 Feb 2008 Moderately Acceptable Not Acceptable Recommended Actions No additional risk control measures required. To continue to monitor to ensure risk do not escalate to higher level. Acceptable to carry out the work activity; however, task need to be reviewed to bring risk level to As Low As Reasonably Practicable. Interim control measures such as administrative controls can be implemented. Supervisory oversight required. Job must not be carried out until risk level is brought to at least medium risk level. Faculty of Engineering Risk controls should not be overly dependant on personal protective equipment. Controls measures should focus on Elimination, substitution and engineering controls. Immediate Management intervention required to ensure risk being brought down to at least medium level before work can be commenced. Safe Operating Procedure (SOP) Project : Highly Efficient Digitally Controlled AC-DC Converter with PFC Capability and Output Voltage Regulation Name : Lim Shu Fan e-mail : [email protected] Tel : 6516-5257 / 6516-2106 Turn on setup 1. Make sure that the external switches connecting the eload and AC source to the DUT are off. 2. Switch on the main power to the DC source, eload and the AC source. 3. Turn on the power of DC source, eload, and AC source with output/input off. 4. Tune the eload (mode CC) and AC source (mode AC) with the required settings of voltage, frequency and current with output/input off. 5. Turn on the external switches connecting the eload and AC source to the DUT. 6. Turn on the output of the DC source. 7. Tune the DC source to above 12.5V. 8. Turn on the output of the AC source. 9. Turn on the input of the eload. Changing load setup 1. Press the knob once to enter the resistance setting mode. 2. Key in required resistance value. 3. Press ENT key. Remember to increase or decrease the resistance in small steps to avoid voltage and current overshoot or undershoot. UNR refers to unregulated state and can be removed once Vin/Iin=R. Changing input AC voltage 1. Turn off the output of the AC source. 2. Press V key to enter voltage setting mode from the home position. 3. Key in the required voltage value and press ENT to confirm. 4. Press ESC key to exit voltage setting mode. 5. Turn on the output of the AC source. To protect the load, it is recommended that the output voltage be set with OUTPUT OFF. Turn off setup 1. Turn off the output of the AC source. 2. Tune the DC source to 0V. 3. Wait till the Vout across bulk capacitor to discharge across the eload resistance till 0V. 4. Turn off the output of the eload. 5. Turn off the external switches connecting the eload and AC source to the DUT. 6. Turn off the output of the DC source. 7. Turn off the power of the AC source, eload and the DC source. 8. Switch off the main power to the AC source, eload and the DC source. June 2009