12 Month Review PresentationAndries J. van der Walt

B-Engineering (Electrical & Electronic) – UJ

Enterprise Park – Electrical Department

Assistant Engineer (EIT)

Mentor: Lerato Mputle

Manager: Lungile Malaza

May 1, 2023

Safety

In case of an emergency:

Stay Calm

Gather personal belongings and move towards exit points

Go to Assembly Points for attendance register check

Fire Extinguishers – Only if Trained

Power Failure – Lights

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Started at Eskom on 01 February 2013.

Completed 6 Month Review on 31 July 2013.

System Processes for B2B: Engineering Operating Model – 6 Weeks

Departmental Rotation: MV Switchgear – 2 Weeks

Smart Plant Electrical (SPEL) – 3 Months

Switchgear Schedules, SLD’s on Matimba Power Station

Presentations

Formal Training: IRM, RCA, RM and I.I., and HIRA. – 4 Weeks

Registered as Candidate Engineer with ECSA and SAIEEE

Introduction

May 1, 2023

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Overview

Formal Training

GSDP Training and Plant Exposure

Electrical Departmental Rotation

Planned Future Training

Conclusion and Lessons Learned

Questions

May 1, 2023

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Formal Training Completed

SharePoint Training – 10 to 12 September 2013.

Hyperwave Training – 19 September 2013.

PCM Training:

Manage Engineering Accountability (MEA) – 6 August 2013

Integrates with the Engineering Business Management PCM

Perform Validation and Verification (V&V) – 21 January 2013

Integrates with the Technical Management PCM

Provide Engineering during Project Sourcing – 31 January 2013

Integrates with the Technical Assurance PCM

May 1, 2023

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Generation Skills Delivery Program (GSDP)

May 1, 2023

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Auxiliary Plant

Coal Plant

Conveyor Belt

Conveyor Equipment

Conveyor Protections

Conveyor Operation

Mills and Mill Feeders

Classifiers

Pulverized Fuel

May 1, 2023

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Auxiliary Plant

Fuel Oil Plant

Purpose and Fuel Type

May 1, 2023

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Auxiliary Plant - Cooling

May 1, 2023

Turbine Auxiliaries

Fire Resistant Fluid

Air Conditioning Plants

Electric boiler Feed pumps

Generator Hydrogen Cooling

Seal Oil Cooling

Generator Stator Cooling

Turbine Lube Oil

Condensate Extraction pumps

Boiler Auxiliaries

Mill Gearbox Lube Oil

Primary Air Fan Lube Oil

Secondary Air Fan Lube Oil

Induced Draught Fan Lube Oil

Generator Hydrogen Cooling

Oil Cooling

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Auxiliary Plant

Compressed Air Systems

Control Air

Service Air

May 1, 2023

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Auxiliary Plant

Different Water Systems

Raw Water

Fire Water System

Potable Water

Demineralized Water

May 1, 2023

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Auxiliary Plant

Hydrogen Plant

Purpose

Hydrogen Production Segment

Hydrogen Preparation Segment

Hydrogen Distribution Segment

May 1, 2023

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Boiler Plant

Types of Boilers:

Natural Circulation Boiler

Assisted Circulation Boiler

Forced Circulation Boiler (Once Through Boiler)

May 1, 2023

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Turbine Plant

May 1, 2023

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Electrical Reticulation

May 1, 2023

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Generation Skills Delivery Program (GSDP)

Self-Management – Dianne le Roux

Presentation Skills – Marina le Grange

Limited Access Register (LAR) – Pieter Hope

Power Station Awareness – Bev Lawrence

Engineering Philosophy - Bev Lawrence

Operating Philosophy – Bev Lawrence

Maintenance Philosophy – Hendrik Smit

May 1, 2023

Electrical Departmental Rotation

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Electrical Departmental Rotation

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Generators – Eugene Kisten

Basic Configuration

May 1, 2023

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Generators

Mechanical- and Electrical Interface Operation Stability Program

Steam forces the turbine to rotate linked to the generator

Rotating at 3000rpm

Electricity is Generated due to electro magnetic induction (Faraday’s Law)

Electricity generated is transferred to HV YARD and to GRID

May 1, 2023

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Generators

Excitation Control Systems

May 1, 2023

GOV

AVR

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Generators

Plant Start-up Process and Procedure

The following components need to be inspected before and while starting up a generator:

Electrical System

Electrical Protections and DC Exciter/AVR System

Oil System: Jacking Oil and Bearing Oil

Cooling System: Hydrogen and Demin Water

Generator parameters

Voltage Set Points (AVR)

Speed / Frequency Set Points

Temperatures: e.g. Winding Temperatures, Oil Temperatures

Vibrations

May 1, 2023

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Generator Protection

Generator Protection

Differential Protection

Stator Earth Fault Protection

Over-Voltage Protection

Under Frequency Protection

Reverse Power Protection

Pole Slipping Protection

Lost of Field Protection

May 1, 2023

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Generator Synchronization

Conditions for Generator Synchronization

Frequency at 50 Hz

Voltage Magnitude

10.5 kV (7 units) & 12.5 kV (2 units) – Komati

16.5 kV – Hendrina

22 kV – Most Common – Kendal, Duvha

Phases

Phase Rotation

Phase Alignment (3 Phase Wave Forms)

May 1, 2023

Generator Tests for LifeX Assessment

• Power Flux Test

• ELCID Tests

• HV Test

• Partial Discharge (PD) Tests

• Tan Delta Tests

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Electrical Departmental Rotation

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AC and DC Essential Systems – David Kunene

UPS

May 1, 2023

Normal Operation

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AC and DC Essential Systems

UPS

May 1, 2023

Bypass Operation

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AC and DC Essential Systems

UPS

May 1, 2023

Abnormal Operation

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AC and DC Essential Systems

DC System Schematic: Normal Conditions

May 1, 2023

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AC and DC Essential Systems

DC System Schematic: Abnormal Conditions

May 1, 2023

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AC and DC Essential Systems

Batteries Types: Nickel-Cadmium- and Lead Acid Batteries

Purpose

Emergency Lighting

Provide Control to Safely Shut down the plant

Safely running down the turbine by providing lubrication for oil pumps

Back up DC Excitation field for generator

Operating Conditions:

25 degrees Celsius and ventilated rooms (HVAC system)

24V, 48V, 220V, 110V

May 1, 2023

Electrical Departmental Rotation

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Motors – Paul Ruthenberg

Types and Application

AC Motors: Induction (Squirrel Cage), Synchronous

DC Motors

Common Voltage Ratings

380V, 3.3kV, 6.6kV, 11kV according to IEC60034-1.

May 1, 2023

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Motors

Manufacturing and Testing

Locked rotor test: Physically locking the rotor with a bar making it unmoveable

Bearing temperature test

Stator winding resistance

IR test: with a 5 kV supply to determine the 10 min/1 min ratio

RTD testing

No Load Test

High Voltage (HV) test

May 1, 2023

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Motors

Variable Speed Drives

Speed control

Energy Saving

Protects the process and motor

Increase Efficiency and control performance

Different control functions if required such as torque and time

May 1, 2023

Softstarters

Reduce mechanical stress on drive-train components.

Ensure smooth acceleration of conveyors.

Suppress water hammer on pumping applications.

Eliminate belt slippage on fan loads.

Lower peak demand charges from the utility.

Electrical Departmental Rotation

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LV Switchgear and Control Gear – Dyke Monyane

Purpose: To control and distribute power to various consumer points for voltage levels less or equal than 1000V AC and 1500V DC.

The AC low voltages generally used are

230 V (single phase loads) e.g. lights

380 V (three phase loads) e.g. three motor, three phase heaters

525 V (Matimba ACC fan boards)

590 V (Majuba ACC fan boards).

The DC low voltages generally used are 24 V, 48 V, 110 V and 220 V depending on the requirements.

May 1, 2023

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LV Switchgear and Control Gear

When sizing the switchgear one should take into consideration the following factors:

Operating Voltage

Short-circuit withstand Current

Current rating

And for each of the above, the following needs to be considered

Load list (from Mechanical) Load Schedule (from Electrical)

Safety Factors

Connected Loads / Running Loads

May 1, 2023

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LV Switchgear and Control Gear

Switchgear Housing

Allowing for additions of more panels

Each circuit in its own compartment (Tier)

Metal Casings

Different Insulation standards depending on MV or LV specifications

Also depending on GIS and AIS specifications

May 1, 2023

Power Station Exposure

Matimba Power Station – for 4 days for the P&ID Refurbishment Project (SPEL).

Komati Power Station – for 1 day for Plant Walk Down.

Kendal Power Station – for GSDP course for 3 of the 10 Weeks

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Planned Future Training

PCM Training:

Engineering interface Management – 17 February 2014.

Design System – 20, 21 February 2014.

Plan Technical Effort – 25 February 2014.

Manage Engineering Technical Risk – 26 February 2014.

Project Work for the Department – 6 Months and onwards

Constructability Review Guidelines and Checklist for Generators – Krishna Naidoo

Vendor Assessment Process and Evaluation Sheet for Generators – Krishna Naidoo

Being seconded for a 1 year to Medupi Power Station on 1 April 2014 - Jacques Prinsloo and Riem de Beer.

May 1, 2023

Planned Training Time Line

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(Complete EIT program)ECSA Pr-Eng

registration

Projects within Electrical Engineering Department

12 month review

Obtain Masters in Electrical

Engineering

31 July 2017

Projects within Electrical

Engineering Department

Going to Medupi Power Station

Back from

Medupi Power Station

1 year

6 months

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Conclusion and Lessons Learned

Hyperwave and SharePoint Training Completed

MEA importance

PCM Training up to date for now

Coal Fired Power station processes and layout – GSDP

Self-management and time management Skills

Completed most of departmental rotation training

Importance of Networking

May 1, 2023

Questions

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?May 1, 2023

Thank you