Task Manual Group Technology VOLTAGE REGULATOR: 32- STEP VOLTAGE SIMPLIFIED

Transcription

Task Manual
Title: VOLTAGE REGULATOR: 32-
Group Technology
Unique Identifier:
34-1218
Part
11 - Maintenance
Area of Applicability:
Distribution Engineering
Documentation Type:
Task Manual
Revision:
0
Total Pages:
21
Next Review Date:
January 2022
STEP VOLTAGE SIMPLIFIED
REGULATOR,
RATING: 11KV.32- STEP
VOLTAGE REGULATOR, 22KV.
CL-2, CL-5A VOLTAGE
REGULATOR CONTROL
Disclosure Classification:
Controlled Disclosure
Compiled by
Approved by (SCOWT SC Chairperson)
Steven da Silva
Peter Busch
Senior Advisor
Transformer CG Chairperson
Date: 08/12/2011
Date: 06/12/2011
Functional Responsibility (Dx)
Authorized by
Colin Smith
Prince Moyo
DTEP Manager
Power Delivery Engineering GM (Acting)
Date: 09/12/2011
Date: 18/12/2011
ESKOM COPYRIGHT PROTECTED
B Morrison / January 2012 / Rev 0
DOCUMENT CLASSIFICATION: CONTROLLED DISCLOSURE
VOLTAGE REGULATOR: 32-STEP VOLTAGE
SIMPLIFIED REGULATOR, RATING: 11KV.32STEP VOLTAGE REGULATOR, 22KV. CL-2, CL5A VOLTAGE REGULATOR CONTROL
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Content
Page
Foreword........................................................................................................................................................3 Introduction ....................................................................................................................................................4 1 Scope ....................................................................................................................................................5 1.1 Purpose ............................................................................................................................................5 1.2 Applicability .......................................................................................................................................5 2 Normative/Informative References .......................................................................................................5 2.1 Normative References ......................................................................................................................5 2.2 Informative References ....................................................................................................................6 3 Definitions and abbreviations ................................................................................................................6 3.1 Definitions .........................................................................................................................................6 3.2 Abbreviations ....................................................................................................................................6 4 Requirements ........................................................................................................................................6 4.1 Responsibilities .................................................................................................................................6 4.2 Plant Managers shall be responsible for: .........................................................................................6 4.3 Each Field Services Manager shall be responsible for: ...................................................................6 4.4 Electricity Delivery Manager shall be responsible for: ......................................................................7 5 Requirements ........................................................................................................................................7 5.1 First and Second Line Maintenance .................................................................................................7 5.2 Specialist Maintenance.....................................................................................................................7 6 Modifications .......................................................................................................................................16 7 Related/Supporting Documents ..........................................................................................................16 7.1 Related Documents ........................................................................................................................16 7.2 Forms and Records ........................................................................................................................16 Annex A - Voltage Regulator Test Certificate ..............................................................................................17 Annex B - Impact assessment .....................................................................................................................18 ESKOM COPYRIGHT PROTECTED
When downloaded from the IARC WEB, this document is uncontrolled and the responsibility rests with the user
to ensure it is in line with the authorised version on the WEB.
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Foreword
The document was compiled to comply with OHSAct requirements and to document the tasks procedure in
maintaining voltage transformers to ensure that maintenance tasks are carried out in a safe manner. This
TASK MANUAL supersedes all the previous Task Manuals / maintenance procedures on Voltage
Regulator: 32-Step Voltage Simplified Regulator, Rating: 11kV 32- Step Voltage Regulator, 22kV CL-2, CL5A Voltage Regulator Control.
VOLTAGE REGULATOR
Revision history
This edition cancels and replaces edition/revision numbers 0 of specification/work instruction no.
SCSINABC4.
Date
Jan 2012
Rev.
0
Clause
-
Jan 2009
0
Jun 2003
0
2
3
4
-
Remarks
Reviewed by: P. A. Busch
Reformatted onto a new template.
Document number changed to DMN 34-1218
Reviewed By: DM Ntombela
The format changed included new information
Normative references updated;
Definitions and abbreviation updated;
Re-numbered all the titles and added more information;
Included Revision History information;
Included impact assessment form;
Reviewed By: DM Ntombela
The format changed included new information
Compiled By: J.G. Kruger
Original issues as SCSINABC4
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Authorisation
This document has been seen and accepted by:
Name
Designation
P Moyo
Power Delivery Engineering GM (Acting)
C Smith
DTEP Manager
P Busch
Transformer Care WG Chairperson
This task manual shall apply throughout Eskom Holdings Limited, its divisions, subsidiaries and entities
wherein Eskom has a controlling interest.
Development team
This TASK MANUAL was previously prepared by:
E O Mutloane
JG Kruger
This TASK MANUAL was revised by:
J Wilson
S Bouwer
JG Kruger
D M Ntombela
This work instruction was revised by:
P. Busch
Introduction
The Task Manual has replaced the Task Manuals within the Distribution Division. This has been done to
assist the end users of these documents and the following is important to note:

The contents of a Task Manual are always linked to the requirements of one or more Job Plans. In
many instances only selected paragraphs / sections of the Task Manual will apply to a specific Job
Plan.

Task Manuals also form the main content of the training module for the task and therefore only
people who have attended the training and assessed as competent should be assigned the task as
described in the Task Manual.
This TASK MANUAL is the revision of the document that was initially compiled and titled “Voltage
Regulator: 32-Step Voltage Simplified Regulator, Rating: 11kV 32- Step Voltage Regulator, 22kV CL-2, CL5A Voltage Regulator Control” to formalize the procedures of performing tasks when carrying maintenance
tasks out. The document includes the latest updates in information, format, safety precautions and
diagrams to make the document more user-friendly.
Keywords
Insulating Oil; Selector; and Contacts
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Bibliography
Not applicable.
1
Scope
1.1
Purpose
The purpose of this TASK MANUAL is to standardise maintenance Task manuals on” Voltage Regulator:
32-Step Voltage Simplified Regulator, Rating: 11kV 32- Step Voltage Regulator, 22kV CL-2, CL-5A Voltage
Regulator Control”.
1.2
Applicability
This document shall apply throughout Eskom Holdings Limited, its divisions, subsidiaries and entities
wherein Eskom has a controlling interest.
2
Normative/Informative References
Parties using this document shall apply the most recent edition of the documents listed below:
2.1
Normative References
Occupational Health and Safety Act and Regulations (OHSAct);
32-406: Mineral Insulating Oils (Uninhibited and Inhibited)
Part 1 Purchase, Management, Maintenance and Testing;
ESKADABC2 (DDR_34-503): Rev 1, Directive on Transformer Oil Sampling and Sample Transportation;
ESKAGAAQ2: Rev 0, The interpretation of Transformer Oil Samples;
DST_32-332: Oil spill clean-up and rehabilitation;
EPC_32-846: Operating Regulations for High Voltage Systems;
DST_34-1710: Provision and use of Personal protective equipment;
SCSPBAAY2 (DPL_34-1005): Rev. 0, Environmental management policy;
DPC_34-908: Procedure for Barricading;
DST_34-1450: Maintenance Of Power Transformer, Reactors, Auxiliaries, Nec's And Necr's;
DPC_34-445: Rev. 0, Standard For The Use Of Equipotential Earth Footplates.
DPC_34-444: Rev. 0, Procedure for the application and maintenance of portable earth’s;
DPC_34-227: Rev. 0, Pre-Task Planning and feedback process; and
ASEA: Transformers Erection,Commissioning,Operation and Maintenance Manual
2.2
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Informative References
DPC_34-04: Procedure For The Preparation And Administration Of Distribution Standards.
3
Definitions and abbreviations
3.1
Definitions
All definitions in EPC_32-846 and OHSAct 85 of 1993 are applicable.
3.2
Abbreviations
PCB: Polychlorinated Biphenyls
CDP: Career Development Programme
PTO: Principal Technical Officer
STO: Senior Technical Officer
TO: Technical Officer
CCC: Change Control Committee
4
Requirements
4.1
Responsibilities
The Designated Person or his delegate, shall ensure that only persons trained and authorized in writing
shall carry out work detailed in this Task Manual.
4.2
Plant Managers shall be responsible for:
a)
Ensuring that equipment job plans are available and issued for specific maintenance.
b)
Ensuring that the maintenance feedback information that is available in the maintenance
management system is analysed.
4.3
Each Field Services Manager shall be responsible for:
a)
Ensuring that staff carrying out maintenance tasks is trained, competent and authorized to
perform maintenance on the specific equipment;
b)
Ensuring that instructions are implemented and adhered to and equipment is maintained in
accordance to relevant Task Manuals.
c)
Ensuring that the maintenance feedback information / data is captured and recorded into the
system for future maintenance planning.
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Electricity Delivery Manager shall be responsible for:
4.4
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a)
Ensuring that trained, competent and authorized staff is available to perform maintenance / tests
on equipment out on maintenance when scheduled;
b)
Ensure that the relevant EDM section is available on site to isolate the equipment AC / DC supply.
5
Requirements
5.1
First and Second Line Maintenance
a)
There shall be maximum and minimum level marks on all gauge glasses.
b)
All gauge glasses shall be clear and legible.
c)
Control boxes shall be clean and dust free. Checks shall be made for any general or obvious
defects.
d)
Control box door and cover seals shall be intact.
e)
Control box heaters shall be operational. If a thermostat is fitted the cut out shall be set at
approximately 25 C.
f)
The operating label shall be securely mounted and shall be legible from the operating position.
g)
All metal work shall be checked for corrosion or rust.
h)
Inspect for any oil leakages
i)
Take an oil sample in accordance to standard ESKASAAF1 for dielectric strength test oil and
moisture content test.
NOTE: All defects found are to be reported to the Work Management Centre with the work order feedback.
5.2
Specialist Maintenance
NOTE: This maintenance can only be done in the Workshop environment where all the necessary equipment like
overhead cranes can be used and inspection can be done. The option for this maintenance is to by-pass / service
exchange the equipment and sends it to the TSG Workshop where the specialized person will do the maintenance.
5.2.1
Pre-planning
5.2.1.1
Material
NOTE: Refer to manufacturer’s manual for screws, nuts, washers, spares, their MR numbers, quantity and sizes.
a)
2 x Drums new transformer oil;
b)
2 x Empty oil drums;
c)
0.5kg lint free cloth;
d)
Approved electrical cleaner;
e)
2 X Contact tips size 2;
f)
2 X Contact tip size 3;
g)
Lock tab;
h)
Contact braid (double);
i)
Contact braid (single);
j)
Stationary contact system;
k)
Movable contact system;
l)
Spring energy accumulator with drive mechanism;
m)
Contact (tungsten-copper);
n)
Contact (tungsten-copper) for transition contact;
o)
Flexible current strips;
p)
Connecting leads;
q)
Contact tip for main switch contact (>200A);
r)
Contact holder;
s)
Pressure plates;
t)
Tubular spacer;
u)
Spring socket; and
v)
Counter-piece.
5.2.1.2
Tools and Equipment
a)
Standard set of tools;
b)
Scaffolding/Ladder;
c)
An oil pump with hoses;
d)
A Drip pan;
e)
Miscellaneous brushes;
f)
Work table; and
g)
A lifting device (crane).
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5.2.1.3
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Personal Protective Equipment
All personal protective equipment shall be in accordance with DST_34-1710.
a)
Overall;
b)
Safety boots;
c)
Fall Arrest System (FAS); and
d)
Gloves.
5.2.2
Safety and Preparations
WARNING: The user of the plant should perform the following safety measures.
a)
Isolate and earth panel in accordance with ESKPVAEY6.
b)
Erect barricading in accordance with DPC_34-908 (where applicable).
c)
Position the vehicle mounted crane as per applicable procedures i.e. DPC_34-445.
d)
Ensure all tools, equipment and materials are placed inside the barricaded area where they will
not hinder or obstruct any worker.
e)
Isolate the D.C. supply to the panel to prevent accidental closing or tripping of the circuit-breaker.
f)
Manually close and open the circuit-breaker from the mechanism box to discharge springs.
g)
Environmental hazards shall be removed in accordance with DST_32-332.
5.2.3
Maintenance procedure
Risk assessment and critical task analysis shall be done in accordance to DPC_34-227 before the
commencement of work and the approved safe work procedures shall be practiced / followed.
The following picture shows the different parts and sections of the voltage regulator (see figure 1).
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Figure 1
5.2.3.1
Operational Checks
a)
Depress the key “8” on the key pad to display compensated voltage (CL4 and CL5 controls only).
b)
Switch the control-switch to manual position.
c)
Switch up the raise switch to initiate a voltage raise operation.
d)
Allow the tapchanger to raise four or five steps or enough to take to the voltage above the in-band
voltage level.
e)
Switch the control-switch to auto position .After the time delay period, the control should cause the
regulator to step down below the top band edge (example SV=120V and BW=2V; top band edge
–121V).The bad edge indicators should now be off.
f)
After the voltage is brought in-band and tap changing has stopped, switch the control switch over
to manual position.
g)
Press down on the lower switch to initiate a lower operation.
h)
Allow the tap changer to lower four or five steps or enough to take to the voltage below the in
band voltage level.
i)
Switch the control switch to auto position. After the time delay period, the control should cause the
regulator to step up above the lower band edge (e.g. SV=1230V and BW=2V; Lower band edge
=119V), the band edge indicators should now be off.
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5.2.3.2
Un-tanking voltage regulator
a)
Put unit in neutral and remove control mounting bolts.
b)
Ensure that voltage regulator is isolated as per EPC_32-846: (ORHVS).
c)
Loosen and remove the jumper connecting bolts and remove the jumpers.
d)
Loosen and remove series arrester securing bolts and remove the arresters (see figure 2).
e)
Mark the top cover in relation to the tank, loosen and remove the cover securing bolts and remove
top cover plate (see figure 2).
Figure 2
f)
Attach the approved sling onto the cover lifting eye bolts and spreader bar
g)
Use the mechanical crane to lift the internal assembly.
NOTE: Avoid lifting core/coil assembly out of oil if possible.
h)
Where the core is not going to be completely un-tanked, place blocks between the cover and tank
lip (see figure 3).
Figure 3
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NOTE: Do not subject tap changer to temperatures above 60 degrees and the unit shall not be left out of oil for
period exceeding four hours.
i)
Where the core must be removed completely out of the tank, ensure that it can be placed in the
oven or in a dry place for that period.
j)
With core removed from the tank clean it inside with electrical cleaner and flush with clean oil.
5.2.3.3
Internal Inspection of Regulator
a)
Check all connections for tightness.
b)
Check all contacts for excessive wear and or pitting (see figure 4).
Figure 4
c)
Flush the transformer / tapchanger unit with approved electrical cleaner to remove the carbon.
d)
Also flush the transformer / tapchanger unit with clean approved oil before assembling the unit
back into the main tank.
e)
Check the bushing gaskets for any leaks and replace if necessary (see figure 5).
Figure 5
f)
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Check the tank cover seal and replace if cracked or damaged (see figure 6).
Figure 6
g)
Check the bushings for any cracks, loose connections at the bottom and replace if necessary (see
figure 7).
Figure 7
h)
The following picture shows the different type of spares needed (see figure 8 and 9).
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Figure 8
Figure 9
5.2.3.4
Re-assembling the Regulator
a)
Assemble the voltage regulator in reverse order.
b)
Put back the unit in tank (tap with mallet or hammer).
c)
Position channels in tank guides and guide control cabinet onto bracket.
d)
Tighten cover bolts and then replace the control-mounting bolt.
e)
Position indicator should show present tap position.
f)
Vacuum fill for one hour (2 mm min.) or 24 hr soak prior to energizing.
g)
Wipe cover gasket surfaces clean.
h)
Make sure that the oil level is correct (see figure 10).
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Figure 10
i)
Check that the position control indicator is on zero before any tests are done (see figure 11).
Figure 11
5.2.3.5
Maintenance on Electronic Control Box
a)
Check the door seal for cracks or perishing and replace it with new one if necessary (see figure
12).
Figure 12
Check that the battery connections are clean and tightened and voltage level is still correct.
b)
Replace the battery with new one when it’s life has reached the end.
c)
Check all other connections to be tightened, clean and rust free (see figure 13).
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Figure 13
5.2.3.6
Testing
In completion of the maintenance test the equipment functionality as per the following steps:
a)
Place the unit inside safely fenced / barricaded area
b)
Ensure that the area has 6.6kV, 11kV and 22kV supply available.
c)
Connect the Source (S) and Source load (SL) with two jumpers from transformer side.
d)
Digital (Push Button) and Analog (variable switch).
e)
Switch the supply on and raise or lower the taps by switching the relevant switch and the
tapchanger react correctly.
6
Modifications
Not applicable
7
Related/Supporting Documents
7.1
Related Documents
a)
Work in Live Chambers and Prohibited areas Critical task analysis:
b)
Training module;
c)
Manufacturers manual.
7.2
Forms and Records
A circuit-breaker report shall be completed. A model report form is given in annex A.
The completed report shall be returned to the Work Management Centre together with the work order via
Work coordinator and a copy thereof shall be sent to or kept at the Technical Specialist Group (TSG).
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Annex A - Voltage Regulator Test Certificate
(normative)
FORM
TITLE
CIRCUIT-BREAKER
FORM
NUMBER
DMN_34-1218
REV DATE
JULY 2014
Distribution Task Manual – Part 11:
DOCUMENT
TITLE
Voltage Regulator: 32-Step Voltage Simplified Regulator,
Rating: 11kV.32- Step Voltage Regulator, 22kV. CL-2, CL5A Voltage Regulator Control.
Substation Name:
Panel:
Serial Number:
Voltage Regulator Make & Type:
Rating:
kV:
Work Order Number:
Control Box Type:
Mark
with X
Counter Movement
Task Done
Yes /
NO
Comments/Results
CL2
CL4
CL5
Phases Test: HV to Winding to Earth
Phases Test: Insulation to Earth Test
Tap changer Lower
Tap changer Raise
Tap changer Auto
Band Limit
Neutral Limit
Series Arrester Connected
Maintained by:…………….………..
Signature: ……………………………
Accepted By: …………………………
Date: …………………………………….
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Annex B - Impact assessment
(normative)
1 Guidelines
o
All comments must be completed.
o
Motivate why items are N/A (not applicable)
o
Indicate actions to be taken, persons or organisations responsible for actions and deadline for
action.
o
Change control committees to discuss the impact assessment, and if necessary give feedback to
the compiler of any omissions or errors.
2 Critical points
2.1
Importance of this document. E.g. is implementation required due to safety deficiencies,
statutory requirements, technology changes, document revisions, improved service quality,
improved service performance, optimized costs.
Comment: Statutory requirements and or document revisions
2.2
If the document to be released impacts on statutory or legal compliance - this need to be
very clearly stated and so highlighted.
Comment: No impact on statutory or legal compliance and mainly document revisions
2.3
Impact on stock holding and depletion of existing stock prior to switch over.
Comment: N/A - No new equipment or item need to be acquired for implementation of this document.
2.4
When will new stock be available?
Comment: N/A –see 2.3 above.
2.5
Has the interchange ability of the product or item been verified - i.e. when it fails is a straight
swap possible with a competitor's product?
Comment: N/A – It is a maintenance document and also see 2.3 above.
2.6
Identify and provide details of other critical (items required for the successful
implementation of this document) points to be considered in the implementation of this document.
Comment: Consult / Refer to equipment maintenance documents when implementing the document.
2.7
Provide details of any comments made by the Regions regarding the implementation of this
document.
Comment: None.
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Annex B
(continued)
3 Implementation timeframe
3.1
Time period for implementation of requirements.
Comment: N/A – No technical changes were made to this document.
3.2
Deadline for changeover to new item and personnel to be informed of DX wide change-over.
Comment: None.
4 Buyers Guide and Power Office
4.1
Does the Buyers Guide or Buyers List need updating?
Comment: NO.
4.2
What Buyer’s Guides or items have been created?
Comment: NONE.
4.3
List all assembly drawing changes that have been revised in conjunction with this
document.
Comment: NONE – The configuration hasn’t changed.
4.4
If the implementation of this document requires assessment by CAP, provide details under 5
Comment: N/A – The revision requires no new equipment.
4.5
Which Power Office packages have been created, modified or removed?
Comment: NONE:
5 CAP / LAP Pre-Qualification Process related impacts
5.1
Is an ad-hoc re-evaluation of all currently accepted suppliers required as a result of
implementation of this document?
Comment: NO
5.2
If NO, provide motivation for issuing this specification before Acceptance Cycle Expiry date.
Comment: N/A – The document doesn’t specify but stipulated the maintenance procedures on the existing
equipment.
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Annex B
(continued)
5.3
Are ALL suppliers (currently accepted per LAP), aware of the nature of changes contained in
this document?
Comment: N/A – The specification document is the document supplied to the suppliers not this one.
5.4
Is implementation of the provisions of this document required during the current supplier
qualification period?
Comment: Yes – This is the revision of document that is presently being implemented and requires no
change to the supplier’s qualification period.
5.5
If Yes to 5.3, what date has been set for all currently accepted suppliers to comply fully?
Comment: N/A – see 5.3 above.
5.6
If Yes to 5.4, have all currently accepted suppliers been sent a prior formal notification
informing them of Eskom’s expectations, including the implementation date deadline?
Comment: N/A – see 5.4 above.
5.7
Can the changes made, potentially impact upon the purchase price of the
material/equipment?
Comment: N/A – No new material / equipment is required.
5.8
Material group(s) affected by specification: (Refer to Pre-Qualification invitation schedule for
list of material groups)
Comment: N/A – No new material is required.
6 Training or communication
6.1
State the level of training or communication required to implement this document. (E.g.
none, communiqués, awareness training, practical / on job, module, etc.)
Comment: Practical / On job and training module.
6.2
State designations of personnel that will require training.
Comment: TSO, PTO & STO.
6.3
Is the training material available? Identify person responsible for the development of
training material.
Comment: Yes – DT- Training is revising earthing related training manual which will address the changes in
this document.
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Annex B
(continued)
6.4
If applicable, provide details of training that will take place. (E.G. sponsor, costs, trainer,
schedule of training, course material availability, training in erection / use of new equipment,
maintenance training, etc).
Comment: Safety and Maintenance training.
6.5
Was Training & Development Section consulted w.r.t training requirements?
Comment: Yes.
7 Special tools, equipment, software
7.1
What special tools, equipment, software, etc will need to be purchased by the Region to
effectively implement?
Comment: NONE.
7.2
Are there stock numbers available for the new equipment?
Comment: N/A – No new equipment is required.
7.3
What will be the costs of these special tools, equipment, software?
Comment: N/A – No new equipment is required.
8 Finances
8.1
What total costs would the Regions be required to incur in implementing this document?
Identify all cost activities associated with implementation, e.g. labour, training, tooling, stock,
obsolescence
Comment:
No costs other than the training will be incurred by the regions and this will depend on the arrangements
made for training ie Training is held regionally or nationally.
Impact assessment completed by:
Name: David M. Ntombela
Designation: Consultant

Task Manual Group Technology VOLTAGE REGULATOR: 32- STEP VOLTAGE SIMPLIFIED

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