CONTROLLED DISCLOSURE

When downloaded from the GDC database, this document is uncontrolled and the responsibility rests with the user
to ensure it is in line with the authorised version on the database.

GENERATOR AND TRANSFORMER ELECTRICAL PROTECTION

INSPECTION AND MAINTENANCE REQUIREMENTS

CONTENTS

PAGES

1.00

PURPOSE

2.00

SCOPE

3.00

DEFINITIONS

4.00

RESPONSIBILITIES

5.00

PROCEDURE

6.00

REFERENCES

7.00

RECORDS

8.00

DISTRIBUTION

9.00

ANNEXURES

REVISION
1

PAGE
OF

CONTROLLED DISCLOSURE
When downloaded from the GDC database, this document is uncontrolled and the responsibility rests with the user
to ensure it is in line with the authorised version on the database.

2
5

GENERATOR AND TRANSFORMER ELECTRICAL PROTECTION

INSPECTION AND MAINTENANCE REQUIREMENTS

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

CONTROLLED DISCLOSURE
When downloaded from the GDC database, this document is uncontrolled and the responsibility rests with the user
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 4
OF
5
RESPONSIBLE

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.

EOD

5.2.2

All LED indications will be recorded on the attached inspection sheet and
presented to PTM for analysis.

EOD

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.

EOD

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.

EOD

5.3.2

All LED indications will be recorded on the attached inspection sheet and
presented to PTM for analysis.

EOD

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.

EOD

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 synchronising:

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.

EOD

5.4.2

Any abnormalities will be recorded on the attached inspection sheet.

EOD

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.

EOD

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 synchronise the unit successfully.

EOD

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/PTM

PTM

CONTROLLED DISCLOSURE
When downloaded from the GDC database, this document is uncontrolled and the responsibility rests with the user
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 5
OF
5
RESPONSIBLE

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.

PTM

5.5.3

EOD must be informed about the intended maintenance.

PTM

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.

PTM & EOD

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!

PTM & EOD

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.

EOD

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.

PTM

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

CONTROLLED DISCLOSURE
When downloaded from the GDC database, this document is uncontrolled and the responsibility rests with the user
to ensure it is in line with the authorised version on the database.

Annexure A
DCI
off

on

Reset

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

CONTROLLED DISCLOSURE
When downloaded from the GDC database, this document is uncontrolled and the responsibility rests with the user
to ensure it is in line with the authorised version on the database.

Annexure B

Main 1
Ch Out
Relay Ready
Trfr Diff Trip
HV Lx BEF Trip
Pole Slip Trip
Gen VT Fuse
Fail
Loss of Field
Trip
Reverse Power
& Over
frequency trip
Under
Frequency Trip
HV Control trip
NPS Trip
Overfluxing Trip
Gen CB High
Temp Trip
SFT 1
Shutdown
UT A E/F 2 Trip
UT A HV O/C
Trip
Ut A 11kV SEF

Ch Out

O
O
O
O
O
O
O

O
O
O
O
O
O
O

02

Relay Healthy

04

Gen Diff Trip

06

HV VT Fuse Fail

14

Reverse Power
2 Trip

Boiler Trip

O
O
O
O
O
O
O
O
O

O
O
O
O
O
O
O
O
O

16

LFP trip

Overfluxing
Stage 1 Alarm

18

Gen CB Pole
Discrepancy

20

Guess Trip

08
10
12

22
24

Gen Over
voltage Trip
Reverse Power
Soft Trip
BU Impedance
Trip

Gen Breaker
Fail Shutdown
HV CB Pole
Discrepancy

26

SFT 2 Shutdown

28

Ut A Diff Trip

30

Ut A 11kV BEF

32

Ut A REF

UT B HV E/F 3
UT B HV O/C
Trip
UT B 11kV SEF
Trip
Gen Trfr HV
BEF Trip
95% Stator E/F
1 or 2 Trip
100% Stator
E/F 2 Trip

Reverse Power
2 Alarm
OFreq H1
Alarm 2
OFreq H2
Alarm 2
OFreq H3 Prot
Deload
UFreq L1 Alarm
2
UFreq L2 Prot
Loading
UFreq L3 Prot
Loading
NPS Alarm

O
O
O
O
O
O
O

O
O
O
O
O
O
O

02

O
O
O
O
O
O
O
O
O

O
O
O
O
O
O
O
O
O

16

04
06
08
10
12
14

18
20
22
24
26
28
30
32

UT B Diff
Trip
UT B 11kV
BEF Trip
UT B 11kV
REF Trip
Gen Trfr HV
REF Trip
100% Stator
E/F 1 Trip
Rotor E/F 1
or 2 Trip
General Trip
FR D21
Reverse
power 1
Alarm
OFreq H1
Alarm 1
OFreq H2
Alarm 1
OFreq H3
Alarm 1
UFreq L1
Alarm 1
UFreq L2
Alarm 1
UFreq L3
Alarm 1
UFreq L41
Alarm 1
Rotor E/F
Alarm

CONTROLLED DISCLOSURE
When downloaded from the GDC database, this document is uncontrolled and the responsibility rests with the user
to ensure it is in line with the authorised version on the database.

Main 1
Ch In
Trip Reset
M2 Gen CB
Crosstrip
HV CB Closed
HV Buszone
Trip
Gen CB
Closed
Turbine Trip
Excitation trip
Unit Brd A Inc
CB Closed

O
O
O
O
O
O
O
O

O
O
O
O
O
O
O
O

Ch In
02

M2 HV CB
Crosstrip

04

Gen CB High
Temp Trip

06

HV CB Open

08

HV CB Control
Trip

10

Gen CB Open

12
14
16

Turbine DCS
Trip
rd
3 Harmonic
Stator E/F
Unit Brd B Inc
CB Closed

Gen Trfr
Buchh or PRD
Trip
Gen winding
Temp Trip
11kV U Brd A
or B Arc Prot
UT A LV earth
Res PRD
UT A Buchh or
PRD Trip
UT A Winding
Temp trip
UT A Earth
Res Oil Temp
UT B Oil Temp
Trip

Ch Out
Gen CB Trip
ESVs Close
Turbine
Shutdown
11kV UB A
Inc CB Trip
Trfr Cooling
Trip

O O

02

O O
O O
O O

04

HV CB Trip

08

O
O
O
O
O
O
O
O

02
04
06
08
10
12
14
16

Gen Trfr TC
Surge Trip
Gen Trfr Oil
Temp Trip
Gen CB Unit
Control Trip
UT A LV Earth
Res Oil Temp
UT A Oil Temp
Trip
UT A LV Earth
Res PRD
UT B Buchh or
PRD Trip
UT B Wind
Temp Trip

CH Out
Gen Field
Suppression
Trip

06

O
O
O
O
O
O
O
O

11kV UB B Inc
CB Trip
HV Breaker Fail
Bustrip

Gen CB Trip
ESVs Close
Turbine
Shutdown
11kV UB A
Inc CB Trip
Trfr Cooling
Trip

O O

02

Gen Field
Suppression
Trip

O O
O O
O O

04

HV CB Trip

06
08

11kV UB B Inc
CB Trip
HV Breaker
Fail Bustrip

CONTROLLED DISCLOSURE
When downloaded from the GDC database, this document is uncontrolled and the responsibility rests with the user
to ensure it is in line with the authorised version on the database.

Main 2
Ch Out
Relay Ready
Trfr Diff Trip
HV Lx BEF Trip
Pole Slip Trip
Gen VT Fuse
Fail
Loss of Field
Trip
Reverse Power
& Over
frequency trip
Under
Frequency Trip
HV Control trip
NPS Trip
Overfluxing Trip
Gen CB High
Temp Trip
SFT 1
Shutdown
UT A E/F 2 Trip
UT A HV O/C
Trip
Ut A 11kV SEF

Ch Out

O
O
O
O
O
O
O

O
O
O
O
O
O
O

02

Relay Healthy

04

Gen Diff Trip

06

HV VT Fuse Fail

14

Reverse Power
2 Trip

Boiler Trip

O
O
O
O
O
O
O
O
O

O
O
O
O
O
O
O
O
O

16

LFP trip

Overfluxing
Stage 1 Alarm

18

Gen CB Pole
Discrepancy

08
10
12

20
22
24

Gen Over
voltage Trip
Reverse Power
Soft Trip
BU Impedance
Trip

Guess Trip
Gen Breaker
Fail Shutdown
HV CB Pole
Discrepancy

26

SFT 2 Shutdown

28

Ut A Diff Trip

30

Ut A 11kV BEF

32

Ut A REF

UT B HV E/F 3
UT B HV O/C
Trip
UT B 11kV SEF
Trip
Gen Trfr HV
BEF Trip
95% Stator E/F
1 or 2 Trip
100% Stator
E/F 2 Trip

Reverse Power
2 Alarm
OFreq H1
Alarm 2
OFreq H2
Alarm 2
OFreq H3 Prot
Deload
UFreq L1 Alarm
2
UFreq L2 Prot
Loading
UFreq L3 Prot
Loading
NPS Alarm

O
O
O
O
O
O
O

O
O
O
O
O
O
O

02

O
O
O
O
O
O
O
O
O

O
O
O
O
O
O
O
O
O

16

04
06
08
10
12
14

18
20
22
24
26
28
30
32

UT B Diff
Trip
UT B 11kV
BEF Trip
UT B 11kV
REF Trip
Gen Trfr HV
REF Trip
100% Stator
E/F 1 Trip
Rotor E/F 1
or 2 Trip
General Trip
FR D21
Reverse
power 1
Alarm
OFreq H1
Alarm 1
OFreq H2
Alarm 1
OFreq H3
Alarm 1
UFreq L1
Alarm 1
UFreq L2
Alarm 1
UFreq L3
Alarm 1
UFreq L41
Alarm 1
Rotor E/F
Alarm

CONTROLLED DISCLOSURE
When downloaded from the GDC database, this document is uncontrolled and the responsibility rests with the user
to ensure it is in line with the authorised version on the database.

Main 2
Ch In
Trip Reset
M2 Gen CB
Crosstrip
HV CB Closed
HV Buszone
Trip
Gen CB
Closed
Turbine Trip
Excitation trip
Unit Brd A Inc
CB Closed

O
O
O
O
O
O
O
O

O
O
O
O
O
O
O
O

Ch In
02

M2 HV CB
Crosstrip

04

Gen CB High
Temp Trip

06

HV CB Open

08

HV CB Control
Trip

10

Gen CB Open

12
14
16

Turbine DCS
Trip
rd
3 Harmonic
Stator E/F
Unit Brd B Inc
CB Closed

Gen Trfr
Buchh or PRD
Trip
Gen winding
Temp Trip
11kV U Brd A
or B Arc Prot
UT A LV earth
Res PRD
UT A Buchh or
PRD Trip
UT A Winding
Temp trip
UT A Earth
Res Oil Temp
UT B Oil Temp
Trip

Ch Out
Gen CB Trip
ESVs Close
Turbine
Shutdown
11kV UB A
Inc CB Trip
Trfr Cooling
Trip

O O

02

O O
O O
O O

04

HV CB Trip

08

O
O
O
O
O
O
O
O

02
04
06
08
10
12
14
16

Gen Trfr TC
Surge Trip
Gen Trfr Oil
Temp Trip
Gen CB Unit
Control Trip
UT A LV Earth
Res Oil Temp
UT A Oil Temp
Trip
UT A LV Earth
Res PRD
UT B Buchh or
PRD Trip
UT B Wind
Temp Trip

CH Out
Gen Field
Suppression
Trip

06

O
O
O
O
O
O
O
O

11kV UB B Inc
CB Trip
HV Breaker Fail
Bustrip

Gen CB Trip
ESVs Close
Turbine
Shutdown
11kV UB A
Inc CB Trip
Trfr Cooling
Trip

O O

02

Gen Field
Suppression
Trip

O O
O O
O O

04

HV CB Trip

06
08

11kV UB B Inc
CB Trip
HV Breaker
Fail Bustrip

CONTROLLED DISCLOSURE
When downloaded from the GDC database, this document is uncontrolled and the responsibility rests with the user
to ensure it is in line with the authorised version on the database.

Annexure C
Pre-job Briefing checklist
Date:
Name: ..
Department: .
Job: ..
No: Question:
1
What needs to be done (purpose, scope and duration)?

Is all staff familiar with this job?

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

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

Was critical risk assessment done?

Is all safety requirements followed (PPE)?

What can be expected on this job?

Tick

Comments

CONTROLLED DISCLOSURE
When downloaded from the GDC database, this document is uncontrolled and the responsibility rests with the user
to ensure it is in line with the authorised version on the database.

Is all documentation (PTW, Procedure, Work Instruction, Plans and

Check sheets) available and completed?

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 (radios etc. ) in working order?

CONTROLLED DISCLOSURE
When downloaded from the GDC database, this document is uncontrolled and the responsibility rests with the user
to ensure it is in line with the authorised version on the database.

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:
Determine the focus of the analysis (include relevant experts) (What job
are you embarking on)

Comments

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?

CONTROLLED DISCLOSURE
When downloaded from the GDC database, this document is uncontrolled and the responsibility rests with the user
to ensure it is in line with the authorised version on the database.

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

CONTROLLED DISCLOSURE
When downloaded from the GDC database, this document is uncontrolled and the responsibility rests with the user
to ensure it is in line with the authorised version on the database.