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 REVISION PAGE 2
INSPECTION AND MAINTENANCE REQUIREMENTS 1 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

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 REVISION PAGE 3
INSPECTION AND MAINTENANCE REQUIREMENTS 1 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 PTM
protection relays. Any abnormalities will be recorded on the attached inspection
sheet. Any findings will be reported to EOD and Electrical Engineering.

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 REVISION PAGE 4
INSPECTION AND MAINTENANCE REQUIREMENTS 1 OF 5
RESPONSIBLE

5.1.2 Weekly inspections will be performed by EOD on the generator and transformer EOD
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 EOD
shutdown of a unit.

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

5.2.3 Both Main 1 and Main 2 protection relays will be reset by pushing the reset EOD
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 EOD
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 EOD
presented to PTM for analysis.

5.3.3 PTM must be notified immediately after a unit trip if the trip originated from an EOD
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 EOD/PTM
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 EOD
protection relays by EOD prior to the synchronising of a unit.

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 EOD
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 EOD
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.

5.5 Maintenance on relays:

5.5.1 A pre-job briefing checklist (Annexure C) as well as a Critical Risk Assessment PTM
(Annexure D) must be completed before any on-load maintenance is performed
on the Main 1 and Main 2 REG 216 Protection relays.

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 REVISION PAGE 5
INSPECTION AND MAINTENANCE REQUIREMENTS 1 OF 5
RESPONSIBLE

5.5.2 Maintenance may be performed on one relay at a time with the production unit PTM
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. PTM

5.5.4 Only one relay can be worked on at a time. It must be made sure by the PTM & EOD
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 PTM & EOD
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 EOD
to PTM.

7.2 PTM will keep the records safe for one year. After one year all accumulated PTM
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

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 Ch Out
UT B Diff
Relay Ready O O 02 Relay Healthy UT B HV E/F 3 O O 02
Trip
UT B HV O/C UT B 11kV
Trfr Diff Trip O O 04 Gen Diff Trip
Trip O O 04
BEF Trip
UT B 11kV SEF UT B 11kV
HV Lx BEF Trip O O 06 HV VT Fuse Fail
Trip O O 06
REF Trip
Gen Over Gen Trfr HV Gen Trfr HV
Pole Slip Trip O O 08
voltage Trip BEF Trip O O 08
REF Trip
Gen VT Fuse Reverse Power 95% Stator E/F 100% Stator
Fail O O 10
Soft Trip 1 or 2 Trip O O 10
E/F 1 Trip
Loss of Field BU Impedance 100% Stator Rotor E/F 1
Trip O O 12
Trip E/F 2 Trip O O 12
or 2 Trip
Reverse Power
Reverse Power General Trip
& Over
frequency trip
O O 14
2 Trip
Boiler Trip O O 14
FR D21
Reverse
Under Overfluxing
Frequency Trip O O 16 LFP trip
Stage 1 Alarm O O 16 power 1
Alarm
Gen CB Pole Reverse Power OFreq H1
HV Control trip O O 18
Discrepancy 2 Alarm O O 18
Alarm 1
OFreq H1 OFreq H2
NPS Trip O O 20 Guess Trip
Alarm 2 O O 20
Alarm 1
Gen Breaker OFreq H2 OFreq H3
Overfluxing Trip O O 22
Fail Shutdown Alarm 2 O O 22
Alarm 1
Gen CB High HV CB Pole OFreq H3 Prot UFreq L1
Temp Trip O O 24
Discrepancy Deload O O 24
Alarm 1
SFT 1 UFreq L1 Alarm UFreq L2
Shutdown O O 26 SFT 2 Shutdown
2 O O 26
Alarm 1
UFreq L2 Prot UFreq L3
UT A E/F 2 Trip O O 28 Ut A Diff Trip
Loading O O 28
Alarm 1
UT A HV O/C UFreq L3 Prot UFreq L41
Trip O O 30 Ut A 11kV BEF
Loading O O 30
Alarm 1
Rotor E/F
Ut A 11kV SEF O O 32 Ut A REF NPS Alarm O O 32
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 Ch In
Gen Trfr
M2 HV CB Gen Trfr TC
Trip Reset O O 02
Crosstrip
Buchh or PRD
Trip
O O 02
Surge Trip
M2 Gen CB Gen CB High Gen winding Gen Trfr Oil
Crosstrip O O 04
Temp Trip Temp Trip O O 04
Temp Trip
11kV U Brd A Gen CB Unit
HV CB Closed O O 06 HV CB Open
or B Arc Prot O O 06
Control Trip
HV Buszone HV CB Control UT A LV earth UT A LV Earth
Trip O O 08
Trip Res PRD O O 08
Res Oil Temp
Gen CB UT A Buchh or UT A Oil Temp
Closed O O 10 Gen CB Open
PRD Trip O O 10
Trip
Turbine DCS UT A Winding UT A LV Earth
Turbine Trip O O 12
rd
Trip Temp trip O O 12
Res PRD
3 Harmonic UT A Earth UT B Buchh or
Excitation trip O O 14
Stator E/F Res Oil Temp O O 14
PRD Trip
Unit Brd A Inc Unit Brd B Inc UT B Oil Temp UT B Wind
CB Closed O O 16
CB Closed Trip O O 16
Temp Trip

Ch Out CH Out
Gen Field Gen Field
Gen CB Trip O O 02 Suppression
Trip
Gen CB Trip O O 02 Suppression
Trip
ESV’s Close ESV’s Close
Turbine
Shutdown
O O 04 HV CB Trip Turbine
Shutdown
O O 04 HV CB Trip

11kV UB A 11kV UB B Inc 11kV UB A 11kV UB B Inc

Inc CB Trip O O 06
CB Trip Inc CB Trip O O 06
CB Trip
Trfr Cooling HV Breaker Fail Trfr Cooling HV Breaker
Trip O O 08
Bustrip Trip O O 08
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 Ch Out
UT B Diff
Relay Ready O O 02 Relay Healthy UT B HV E/F 3 O O 02
Trip
UT B HV O/C UT B 11kV
Trfr Diff Trip O O 04 Gen Diff Trip
Trip O O 04
BEF Trip
UT B 11kV SEF UT B 11kV
HV Lx BEF Trip O O 06 HV VT Fuse Fail
Trip O O 06
REF Trip
Gen Over Gen Trfr HV Gen Trfr HV
Pole Slip Trip O O 08
voltage Trip BEF Trip O O 08
REF Trip
Gen VT Fuse Reverse Power 95% Stator E/F 100% Stator
Fail O O 10
Soft Trip 1 or 2 Trip O O 10
E/F 1 Trip
Loss of Field BU Impedance 100% Stator Rotor E/F 1
Trip O O 12
Trip E/F 2 Trip O O 12
or 2 Trip
Reverse Power
Reverse Power General Trip
& Over
frequency trip
O O 14
2 Trip
Boiler Trip O O 14
FR D21
Reverse
Under Overfluxing
Frequency Trip O O 16 LFP trip
Stage 1 Alarm O O 16 power 1
Alarm
Gen CB Pole Reverse Power OFreq H1
HV Control trip O O 18
Discrepancy 2 Alarm O O 18
Alarm 1
OFreq H1 OFreq H2
NPS Trip O O 20 Guess Trip
Alarm 2 O O 20
Alarm 1
Gen Breaker OFreq H2 OFreq H3
Overfluxing Trip O O 22
Fail Shutdown Alarm 2 O O 22
Alarm 1
Gen CB High HV CB Pole OFreq H3 Prot UFreq L1
Temp Trip O O 24
Discrepancy Deload O O 24
Alarm 1
SFT 1 UFreq L1 Alarm UFreq L2
Shutdown O O 26 SFT 2 Shutdown
2 O O 26
Alarm 1
UFreq L2 Prot UFreq L3
UT A E/F 2 Trip O O 28 Ut A Diff Trip
Loading O O 28
Alarm 1
UT A HV O/C UFreq L3 Prot UFreq L41
Trip O O 30 Ut A 11kV BEF
Loading O O 30
Alarm 1
Rotor E/F
Ut A 11kV SEF O O 32 Ut A REF NPS Alarm O O 32
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 Ch In
Gen Trfr
M2 HV CB Gen Trfr TC
Trip Reset O O 02
Crosstrip
Buchh or PRD
Trip
O O 02
Surge Trip
M2 Gen CB Gen CB High Gen winding Gen Trfr Oil
Crosstrip O O 04
Temp Trip Temp Trip O O 04
Temp Trip
11kV U Brd A Gen CB Unit
HV CB Closed O O 06 HV CB Open
or B Arc Prot O O 06
Control Trip
HV Buszone HV CB Control UT A LV earth UT A LV Earth
Trip O O 08
Trip Res PRD O O 08
Res Oil Temp
Gen CB UT A Buchh or UT A Oil Temp
Closed O O 10 Gen CB Open
PRD Trip O O 10
Trip
Turbine DCS UT A Winding UT A LV Earth
Turbine Trip O O 12
rd
Trip Temp trip O O 12
Res PRD
3 Harmonic UT A Earth UT B Buchh or
Excitation trip O O 14
Stator E/F Res Oil Temp O O 14
PRD Trip
Unit Brd A Inc Unit Brd B Inc UT B Oil Temp UT B Wind
CB Closed O O 16
CB Closed Trip O O 16
Temp Trip

Ch Out CH Out
Gen Field Gen Field
Gen CB Trip O O 02 Suppression
Trip
Gen CB Trip O O 02 Suppression
Trip
ESV’s Close ESV’s Close
Turbine
Shutdown
O O 04 HV CB Trip Turbine
Shutdown
O O 04 HV CB Trip

11kV UB A 11kV UB B Inc 11kV UB A 11kV UB B Inc

Inc CB Trip O O 06
CB Trip Inc CB Trip O O 06
CB Trip
Trfr Cooling HV Breaker Fail Trfr Cooling HV Breaker
Trip O O 08
Bustrip Trip O O 08
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: 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?

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.
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?

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: 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?

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.