gen relay panel flag sheet 4345

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to ensure it is in line with the authorised version on the database.



GENERATOR AND TRANSFORMER ELECTRICAL PROTECTION INSPECTION AND MAINTENANCE REQUIREMENTS

REVISION 1

PAGE 2 OF 5

CONTENTS PAGES

1.00 PURPOSE 3 2.00 SCOPE 3 3.00 DEFINITIONS 3 4.00 RESPONSIBILITIES 3 5.00 PROCEDURE 3 6.00 REFERENCES 5 7.00 RECORDS 5 8.00 DISTRIBUTION 5 9.00 ANNEXURES 5




REVISION 1

PAGE 3 OF 5 RESPONSIBLE

1.00 PURPOSE

Assurance of the availability and reliability of the Generator and Generator Transformer Electrical Protection system.

2.00 SCOPE

The REG216 protection systems installed on units 1 to 6. Two modules are installed per unit. The two units are referred to as Main 1 (situated on BAY1 RP1) and Main 2 (situated on BAY2 RP2). Both Main 1 and main 2 are exact duplicates of each other and can function 100% independently from each other. Both units should at all times be in service to ensure optimal protection of the system. One relay will always perform the back-up function for the other relay.

3.00 DEFINITIONS 3.1 PTM - Protection Department 3.2 EOD - Electrical Operating Desk 3.3 LED - Light Emitting Diode 4.00 RESPONSIBILITIES 4.1 PTM

PTM is responsible for periodic maintenance, function checks and modification implementation. Drawing maintenance forms an integral part of this responsibility.

4.2 EOD

EOD is responsible for incident recordings, incident reporting to PTM, Production management and Electrical Engineering as well as ensuring the availability of the generator and transformer protection system at all times.

4.3 Electrical Engineering

Electrical Engineering is responsible for the long term health, reliability and availability of the protection system. All modifications will be approved by Electrical Engineering before implementation.

5.00 PROCEDURE 5.1 Periodic inspections: 5.1.1 Monthly inspections will be performed by PTM to ensure the availability of the protection relays. Any abnormalities will be recorded on the attached inspection sheet. Any findings will be reported to EOD and Electrical Engineering.

PTM




REVISION 1


5.1.2 Weekly inspections will be performed by EOD on the generator and transformer protection system to ensure the availability and reliability of the system. Any abnormalities will be recorded on the attached inspection sheet (annexure B). 5.2 Inspections after normal unit shutdowns: 5.2.1 An inspection on the generator protection system will be performed after the shutdown of a unit. 5.2.2 All LED indications will be recorded on the attached inspection sheet and presented to PTM for analysis. 5.2.3 Both Main 1 and Main 2 protection relays will be reset by pushing the reset buttons (see figure 1 on Annexure A) situated above each relay. 5.3 Inspections after an automatic unit trip: 5.3.1 An inspection will be performed on the generator protection system after any unit trip, be it an electrical or mechanical originated trip. 5.3.2 All LED indications will be recorded on the attached inspection sheet and presented to PTM for analysis. 5.3.3 PTM must be notified immediately after a unit trip if the trip originated from an electrical problem. PTM should also be notified if the trip origin is unclear. 5.3.4 In the instance of an automatic unit trip in which the origin of the trip is electrical or uncertainty exist with regards to the origin of the trip, only PTM personnel are allowed to reset the Main 1 and Main 2 trip relays or to give permission for the relays to be reset. 5.4 Inspections prior to every unit synchronisi ng: 5.4.1 An inspection on the generator protection system will be performed on the protection relays by EOD prior to the synchronising of a unit. 5.4.2 Any abnormalities will be recorded on the attached inspection sheet. 5.4.3 Any abnormalities indicating that any one or both of the protection relays is/are unhealthy must be immediately reported to PTM. Relays must not be reset if the relays are not healthy. 5.4.4 If both relays are healthy, both relays must be reset by pushing the reset buttons situated above each relay (see figure 1 on Annexure A). Failure to do so will result in the failure to sy nchronise the unit successfully. 5.5 Maintenance on relays: 5.5.1 A pre-job briefing checklist (Annexure C) as well as a Critical Risk Assessment (Annexure D) must be completed before any on-load maintenance is performed on the Main 1 and Main 2 REG 216 Protection relays.

EOD

EOD

EOD

EOD

EOD

EOD

EOD

EOD/PTM

EOD

EOD

EOD

EOD

PTM




REVISION 1


5.5.2 Maintenance may be performed on one relay at a time with the production unit on load. Before any maintenance is performed, the attached pre-job and critical risk check sheet must be completed. 5.5.3 EOD must be informed about the intended maintenance. 5.5.4 Only one relay can be worked on at a time. It must be made sure by the maintenance personnel and EOD that the relay that is not worked on is 100% healthy. 5.5.5 On completion of the maintenance, it must be made sure by EOD and PTM maintenance that the relay that was worked on is 100% healthy, no trips are active on it and that both DC power supplies to the relay is switched on! 6.00 REFERENCES 6.1 ABB REG216 User manual.

6.2 Protection drawings.

6.3 Protection settings document.

7.00 RECORDS 7.1 All documentation completed during maintenance activities must be presented to PTM.

7.2 PTM will keep the records safe for one year. After one year all accumulated documentation must be compiled in book format and archived in the Matla Documentation centre.

8.00 DISTRIBUTION

Will be available on “EDMS” and “G-drive” (G:\data\Omop) as soon as the document is signed by all stakeholders.

9.00 ANNEXURES

Annexure A - Reset push button and relay front face Annexure B - Main 1 and Main 2 check sheets Annexure C - Pre-job Briefing checklist Annexure D - Critical Risk assessment

PTM

PTM

PTM & EOD

PTM & EOD

EOD

PTM



Annexure A

DCI Figure 1 Trip reset button relative to Protection relay position on panel

Reset on off



Annexure B

Main 1

Ch Out Ch Out

Relay Ready O O 02 Relay Healthy UT B HV E/F 3 O O 02 UT B Diff Trip

Trfr Diff Trip O O 04 Gen Diff Trip UT B HV O/C Trip O O 04 UT B 11kV

BEF Trip

HV Lx BEF Trip O O 06 HV VT Fuse Fail UT B 11kV SEF Trip O O 06 UT B 11kV

REF Trip

Pole Slip Trip O O 08 Gen Over voltage Trip Gen Trfr HV

BEF Trip O O 08 Gen Trfr HV REF Trip

Gen VT Fuse Fail O O 10 Reverse Power

Soft Trip 95% Stator E/F 1 or 2 Trip O O 10 100% Stator

E/F 1 Trip Loss of Field

Trip O O 12 BU Impedance Trip 100% Stator

E/F 2 Trip O O 12 Rotor E/F 1 or 2 Trip

Reverse Power & Over

frequency trip O O 14 Reverse Power

2 Trip Boiler Trip O O 14 General Trip FR D21

Under Frequency Trip O O 16 LFP trip Overfluxing

Stage 1 Alarm O O 16 Reverse power 1 Alarm

HV Control trip O O 18 Gen CB Pole Discrepancy Reverse Power

2 Alarm O O 18 OFreq H1 Alarm 1

NPS Trip O O 20 Guess Trip OFreq H1 Alarm 2 O O 20 OFreq H2

Alarm 1

Overfluxing Trip O O 22 Gen Breaker Fail Shutdown OFreq H2

Alarm 2 O O 22 OFreq H3 Alarm 1

Gen CB High Temp Trip O O 24 HV CB Pole

Discrepancy OFreq H3 Prot Deload O O 24 UFreq L1

Alarm 1 SFT 1

Shutdown O O 26 SFT 2 Shutdown UFreq L1 Alarm 2 O O 26 UFreq L2

Alarm 1

UT A E/F 2 Trip O O 28 Ut A Diff Trip UFreq L2 Prot Loading O O 28 UFreq L3

Alarm 1 UT A HV O/C

Trip O O 30 Ut A 11kV BEF UFreq L3 Prot Loading O O 30 UFreq L41

Alarm 1

Ut A 11kV SEF O O 32 Ut A REF NPS Alarm O O 32 Rotor E/F Alarm



Main 1

Ch In Ch In

Trip Reset O O 02 M2 HV CB Crosstrip

Gen Trfr Buchh or PRD

Trip O O 02 Gen Trfr TC

Surge Trip

M2 Gen CB Crosstrip O O 04 Gen CB High

Temp Trip Gen winding Temp Trip O O 04 Gen Trfr Oil

Temp Trip

HV CB Closed O O 06 HV CB Open 11kV U Brd A or B Arc Prot O O 06 Gen CB Unit

Control Trip HV Buszone

Trip O O 08 HV CB Control Trip UT A LV earth

Res PRD O O 08 UT A LV Earth Res Oil Temp

Gen CB Closed O O 10 Gen CB Open UT A Buchh or

PRD Trip O O 10 UT A Oil Temp Trip

Turbine Trip O O 12 Turbine DCS Trip UT A Winding

Temp trip O O 12 UT A LV Earth Res PRD

Excitation trip O O 14 3rd Harmonic Stator E/F UT A Earth

Res Oil Temp O O 14 UT B Buchh or PRD Trip

Unit Brd A Inc CB Closed O O 16 Unit Brd B Inc

CB Closed UT B Oil Temp Trip O O 16 UT B Wind

Temp Trip

Ch Out CH Out

Gen CB Trip O O 02 Gen Field

Suppression Trip


Suppression Trip

ESV’s Close Turbine

Shutdown O O 04 HV CB Trip



11kV UB A Inc CB Trip O O 06 11kV UB B Inc

CB Trip 11kV UB A Inc CB Trip O O 06 11kV UB B Inc

CB Trip Trfr Cooling

Trip O O 08 HV Breaker Fail Bustrip Trfr Cooling

Trip O O 08 HV Breaker Fail Bustrip



Main 2

Ch Out Ch Out

Relay Ready O O 02 Relay Healthy UT B HV E/F 3 O O 02 UT B Diff Trip

Trfr Diff Trip O O 04 Gen Diff Trip UT B HV O/C Trip O O 04 UT B 11kV

BEF Trip

HV Lx BEF Trip O O 06 HV VT Fuse Fail UT B 11kV SEF Trip O O 06 UT B 11kV

REF Trip

Pole Slip Trip O O 08 Gen Over voltage Trip Gen Trfr HV

BEF Trip O O 08 Gen Trfr HV REF Trip

Gen VT Fuse Fail O O 10 Reverse Power

Soft Trip 95% Stator E/F 1 or 2 Trip O O 10 100% Stator

E/F 1 Trip Loss of Field

Trip O O 12 BU Impedance Trip 100% Stator

E/F 2 Trip O O 12 Rotor E/F 1 or 2 Trip

Reverse Power & Over

frequency trip O O 14 Reverse Power

2 Trip Boiler Trip O O 14 General Trip FR D21

Under Frequency Trip O O 16 LFP trip Overfluxing

Stage 1 Alarm O O 16 Reverse power 1 Alarm

HV Control trip O O 18 Gen CB Pole Discrepancy Reverse Power

2 Alarm O O 18 OFreq H1 Alarm 1

NPS Trip O O 20 Guess Trip OFreq H1 Alarm 2 O O 20 OFreq H2

Alarm 1

Overfluxing Trip O O 22 Gen Breaker Fail Shutdown OFreq H2

Alarm 2 O O 22 OFreq H3 Alarm 1

Gen CB High Temp Trip O O 24 HV CB Pole

Discrepancy OFreq H3 Prot Deload O O 24 UFreq L1

Alarm 1 SFT 1

Shutdown O O 26 SFT 2 Shutdown UFreq L1 Alarm 2 O O 26 UFreq L2

Alarm 1

UT A E/F 2 Trip O O 28 Ut A Diff Trip UFreq L2 Prot Loading O O 28 UFreq L3

Alarm 1 UT A HV O/C

Trip O O 30 Ut A 11kV BEF UFreq L3 Prot Loading O O 30 UFreq L41

Alarm 1

Ut A 11kV SEF O O 32 Ut A REF NPS Alarm O O 32 Rotor E/F Alarm



Main 2

Ch In Ch In

Trip Reset O O 02 M2 HV CB Crosstrip

Gen Trfr Buchh or PRD

Trip O O 02 Gen Trfr TC

Surge Trip

M2 Gen CB Crosstrip O O 04 Gen CB High

Temp Trip Gen winding Temp Trip O O 04 Gen Trfr Oil

Temp Trip

HV CB Closed O O 06 HV CB Open 11kV U Brd A or B Arc Prot O O 06 Gen CB Unit

Control Trip HV Buszone

Trip O O 08 HV CB Control Trip UT A LV earth

Res PRD O O 08 UT A LV Earth Res Oil Temp

Gen CB Closed O O 10 Gen CB Open UT A Buchh or

PRD Trip O O 10 UT A Oil Temp Trip

Turbine Trip O O 12 Turbine DCS Trip UT A Winding

Temp trip O O 12 UT A LV Earth Res PRD

Excitation trip O O 14 3rd Harmonic Stator E/F UT A Earth

Res Oil Temp O O 14 UT B Buchh or PRD Trip

Unit Brd A Inc CB Closed O O 16 Unit Brd B Inc

CB Closed UT B Oil Temp Trip O O 16 UT B Wind

Temp Trip

Ch Out CH Out


Suppression Trip


Suppression Trip





11kV UB A Inc CB Trip O O 06 11kV UB B Inc

CB Trip 11kV UB A Inc CB Trip O O 06 11kV UB B Inc

CB Trip Trfr Cooling

Trip O O 08 HV Breaker Fail Bustrip Trfr Cooling

Trip O O 08 HV Breaker Fail Bustrip



Annexure C Pre-job Briefing checklist

Date: ………………………………………………… Name: ……….………………………………………. Department: …………………………………………. Job: ………………………………………………….. No: Question: Tick Comments 1 What needs to be done (purpose, scope and duration)?

2 Is all staff familiar with this job?

3 What impact can this job have on the plant? (What can go wrong)

4 Who is going to do what (Roles and responsibilities)?

5 Was critical risk assessment done?

6 Is all safety requirements followed (PPE)?

7 What can be expected on this job?



8 Is all documentation (PTW, Procedure, Work Instruction, Plans and Check sheets) available and completed?

9 Were relevant documents discussed with all stakeholders?

10 What were the previous lessons learned when doing this job?

11 What are the human error traps in this situation?

12 Are all communication devices (radio’s etc. ) in working order?



Annexure D

Date: Name: Department:

Job: PM No: HP Ref No:

(HP Ref will be filled in by the HP department)

Critical Risk Assessment

Question: Comments Determine the focus of the analysis (include relevant experts) (What job

are you embarking on)

What are the risks when doing this job that may have an impact on people, plant, or might it lead to load loss or a unit trip?

Identify problems that might occur?

Identify the contributing factors for each problem that might occur?

What can you do to reduce the chances of the identified problems occurring/eliminate the problems form occurring?



How can you minimise the effects of a problem that might occur?

Make sure that everybody understands what needs to be done to reduce the risk of an incident/problem as a result of an action, plan or decision.

Evaluate the level of impact that the suggested action plan will have on station performance. (Trip, safety. Load loss, plant damage, etc) High, low medium risk?

Do a TWIN analyses to minimise the impact of human error on the critical task?

� Task difficulty � Work environment � Individual ability � Human nature

gen relay panel flag sheet 4345

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