18 Months- Performance Assessment Engineer In Training (EIT)

Group Technology Electrical Plant Engineering

B.Eng. Electrical and Electronic Engineering

University of Johannesburg

Grade L11

Compiled by Shandukani Vhulondo

Unique No: 4099583

Content

• Introduction

• Summary of the work done in previous 6 Months

• Summary of the Previous Project Work done in 12 Months

• Duvha FAT for MV Switchgear Replacement

• Majuba MV Switchgear Replacement Project

• Kriel Fabric Filter Plant Project

• Course Attended

• Applicable Standards Used

• Conclusion

• Acknowledgement

• Question and Answer

27/05/2013 2

Introduction

• A bit about myself

• Hometown – Venda (Makhado)

• Qualification obtained in 2011

• Appointed as an EIT 1st November -2011

• Joined Group Technology Electrical Department 1st November 2011

• Registered with ECSA as Candidate Engineer – January 2012

• Occupation: Assistant Electrical Engineer

• Aspiration is to obtained PrEng Elec (Eng) with ECSA

• Master of Engineering, M.Eng Elec (Eng)

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Summary of the work done in previous 6 Month

LV induction motor energy classic (IE2, IE3) power saving and energy efficiency Project ( 2.5 Month)

Objective: To compare different manufacturers that produce IE1 and IE2 LV Energy Efficiency motors and determine which of this manufacture has high efficiency, power saving, energy saving and high power factor when operated at 100% full load.

Knowledge and Skills gained

•Energy Efficiency of different energy class motor (IE1, IE2)

•Power factor comparison per hear for both IE1 and IE2

•Soft start for LV induction Motor, Power and Energy Saving Cost per year for both IE1 and IE2

•Power saving in Rand /Year for both IE1 and IE2

•Efficiency comparison for IE1 and IE2 at 100% full load,

•Efficiency Testing Measurements Method

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Summary of the work done in previous 6 Month

Generator Stabilities and Excitation Control Systems Project

•Objective: to learn how Generator Excitation Control Systems in a power station and voltage stability using AVR.

•Deliverables/ Knowledge and Skills Gained ( 3.5 Month)

•The effect of lagging and leading power factor in generator

•Generator stability

•Generator Excitation Systems

•South Africa Grid Code Compliance-Generator Excitation Systems

•Power Factor meter

•Generator Synchronization

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Summary of the Previous 12 Month Project Work done

Summary of the Projects done over 12 Months Period Item No Project Scope Outcomes Mentor Duration Comment

1Comparison of Low Voltage Energy Efficiency Class for

Induction Motorsto conduct phisibility comparison studies of LV

energy efficiency classes (IE1, IE2, IE3)

Demonstrate an understanding of: a) Motor types and their applicationb) Purpose of motor processes, standards and specification.c) Manufacturing and testing of motorsd) Motor protection requirementse) Safety requirement during commissioning and operation of motors

Dr Marubini (Chief Electrical Engineer GTE Plant Engineering ) Mentor

24-Jan-2012 to 04 March-2012 completed

2Generator Excitation Control

SystemsGenerator Capability Chart and Excitation Control

Systems

Demonstrate an understanding of: a) Excitation Control Systemsb) Purpose of AVR c) South African Grid Code (SAGC)d) Generator synchronousatione) Voltage Stability of Generator and Generator operation limits control during in-service (f) Eskom generator interfaces and AVR

Wayne Anthony Smith (Electrical Engineer) Mentor

14-Nov-2011 to 01-Jan-2012 completed

3 Temporary Power Supply Design of Temporary power supply from Mini-Sub PP to the water treatment plant

Demonstrate an understanding of: a) Cable Types and their applicationb) Purpose of cable sizing, standards and specification.c) Manufacturing and testing of Power Cabled) Process of Cable routing and racking, trenchinge) Safety requirement during commissioning and operation of motors (f) Site acceptance testing- Types of test(g) Cable earthing, excavation

Jacques Prinsloo (Electrical Lead Project Engineer) and Mathys Taljaard (Electrical

Engineer GTE)

01 April-2012 to 04 June - 2012

completed (but with reservation)

4

Energy Consumption in a week for the H-Block Building when Lights and Air conditioners are left on after working hours

The study has been restricted to lights,air conditioning in H block. Other appliances like fridges are required to be on all the time. The

consumption from laptops can be considered to be negligible. After hours has been defined from

17:00 to 06:00 and a 24 hour period

Demonstrate an understanding of: a) Energy comparison between actual measured and theoretical measurementsb) Determine the possible energy saving methodc) Power Consumption during off business hours d) Actual cost of the energy consumption during off business hours when lights and air condition are on.e) Recommendation based on the studies

Jacques Prinsloo (Electrical Lead Project Engineer) Coach 04-June- 2012 to 13 July completed

5Medupi Power Station Underground Earthing Inspection Project

The objective was to inspect and approve ITPs for earthing inspection for both Unit 1 ACC and Fabric Filter plant (main civil works package 08)

for contractors

Demonstrate an understanding of: a) Earthing inspection for Unit 1 Column C in Boiler Houseb) Earthing inspection of Unit 1 Coummn A in Boiler Housec) Earthing inspection for Unit 1 Fabric Filter Plant FFPd) Visual inspection on connection methods e) Recommendation based on the standards and specifcation

Mathys Taljaard (Electrical Engineer GTE) Coach

02-July-2012 to 13 July 2012 Completed

6ARNOT MV SWITCHGEAR REPLACEMENT PROJECT BASIC DESIGN REPORT

There is MV Switchgear Replacement that is being done at Arnot Power Station. I am

responsible for the reviewing the basic design report.

Demonstrate an understanding of: a) Demonstrate the understanding of Basic design b) Tender Evaluation to the contractorc) The electrical reticulation at the Power Stationd) Design criterial, specification, standard and governancee) Protection Scheme (f) Site Acceptance Test (G) Factory Acceptance test (I) HV regulation

Elekanyani Ndlovu ( Lead Discipline Engineer) (Senior Electrical Engineer)

Coach

08- October 2012 to 29 October 2012 completed

7

Medupi Power Station MV Voltage Switchgear Factory Acceptance Test

To conduct Inspection and perfoming functional checks and as well as examining the boards if

they are erected according to the Eskom specification and Complience to the IEC

standards for MV Switchgear

Demonstrate an understanding of: a) Demonstrate functional check on the alarm tripping systems b) functional test for the test block c) Protection Schemes functionsd) Inspection of the Internal Arc Classificatione) Complience of MV Switchgear HV regulation

Makgatle Lentsoane ( Electrical Engineer Engineering GTE)

17 -September -2012 to 20 Sepember 2012 completed

6

23-05-01 7

Generation Skills and Develop Program (GSDP) Power Station

Awareness        Courses Date Presentation/ Assessment Outcomes Status

1. Self Management 16/07/2012 to 20/07/2012

Assessment Exam Demonstration of effective presentation skills in the form of presenting to the lecture and class mates Completed

2. Power Station Awareness

19/07/2012 to 19/07/2012

Power Station Layout and Plant Criticality To demonstrate understanding in Ash overland converyors, stocking and spreading, milling plant, Draught Group, Boiler Auxiliaries, HP Pipework, Sub-merged Scraper Conveyor, Precipitators

Completed

3. Auxiliary Plant Theory and practical 23/07/2012 to 26/07/2012

Dry Ash Handling System To demonstrate understanding of Auxiliary Plants in the form of plant work down and classroom assignment report

Completed

4. Presentation skills30/07/2012 to 31/07/2012

Effective Presentation Assessment To demonstrate understanding and knowledge of presentation skills in the form of short presentation to the class in the presence of facilitator

Completed

5. Boiler Plant theory and practical 07/08/2012 to 13/08/2012

Water and Steam Flow in a Once Through Boiler To demonstrate understanding and knowledge of Boiler Plant theory in the form of plant work down and assignment coupled with presentation for the boiler plant

Completed

6. Turbine Plant theory and practical 21/08/2012 to 24/08/2012

Turbine Gland Steam Sealing SystemsTo demonstrate the Turbine auxiliaries, Turbine Center Line, Feed water Condensate and Main Cooling Water System in form of plant work down and assisgnment

Completed

7. Electrical reticulation theory and practical 06/09/2012 to 07/09/2012

SynchronisationTo demonstrate understanding in Operating and Engineering Philosophy. Plant work down and

theoretical examination Completed

8. Operating and Engineering Philosophy 10/09/2012 to 11/09/2012

Case Study To demonstrate understanding in Operating and Engineering Philosophy. Plant work down and theoretical examination

Completed

9. Simulator 17/09/2012 to 17/09/2012

Practical Exposure to the Duvha Power Station,HV yard and Distribution network interface

Completed

10. Maintenance Philosophy 18/09/2012 to 18/09/2012

Case Study Understanding Maintenance philosophies

Completed

Summary of the Previous 12 Month Project Work done

Duvha FAT for MV Switchgear Replacement

• Background: Factory Acceptance Test for MV Switchgear of Duvha Power Station

• Objective: To be able to perform continuity test on MV Switchgear board

• Knowledge/ Skills gained

I witnessed the following tests/checks:

•  Routine testing of CT and VT’s.

• Functional checks.

• Alarm indications

• Point-to-Point (continuity) checks

• Circuit breaker testing

• Interlocking checks, Arc protection relay testing

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Majuba MV Switchgear Replacement Project

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Majuba MV Switchgear Replacement Project

Background

Majuba’s unit 1-3 and common plant consist of M&G MV Switchgear which has come to the end of its design life (oldest 25 years), Unit 4-6 has ABB Uni-gear MV Switchgear installed (oldest 16 years

Objectives: the involvement on the project was to gain exposure on MV and LV Switchgear

Knowledge/ Skills Gained

• Different types of MV Switchgear (AIS, GIS, RMUs, Minisubs)

•Air Insulated Switchgear vs Gas Insulated Switchgear

•Switchgear Construction

•Technology Selection

20/05/20131027/05/2013

Majuba MV Switchgear Replacement Project

Assisted in Switchgear Design Guideline which will assist engineers in the design of

•MV Switchgear during the concept and basic design phases

•Interfaces with switchgear.

•Interface with HVAC (cooling)

•Interface with Civil work

•Interfaces with Cabling

•Interfaces with Metering an Measurements

•RAR design review

•Uninterruptable Power Supplies (UPS)

•Battery Chargers and Batteries

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Majuba MV Switchgear Replacement Project

I have gained the following experience which is not related to technical:

• I assisted in the development of project schedules and hours spent per activity.

•I gained knowledge on project management terms.

•I participated in the discussions regarding the schedule in the Primevera Software.

•I understand what information required in a switchgear replacement project.

• Involve in MV Switchgear Design Guideline which will assist engineers in the design of MV Switchgear during the concept and basic design phases.

•Desiel Generator

27/05/2013

Kriel Fabric Filter Plant

Background:

•Kriel Power Station’s current Atmospheric Emissions License limit of 125 mg/Nm3 will be reduced to 50 mg/Nm3 by 2020 as set out in the Atmospheric Emission Licence from 31/05/2012

Objective : was to investigate the different supply concepts of the ID Fan and Cleaning Air Equipment for the proposed Kriel Fabric Filter Plant

Knowledge/ Skills gained

•Sizing of Transformers

•Sizing of transformer incomer LV Power Cable

•Sizing of transformer feeder MV Power Cable

•Selecting the cable sizing according to the Aberdare Cable Sizing Guideline.

•

.

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Kriel Fabric Filter Plant Cont…..

• Understand the purpose of the different electrical components which forms part of switchgear.

• Understand the purpose of the different electrical components which forms part of switchgear.

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Applicable Standards and Specification used

• 240-56227426 : Generation MV and LV protection philosophy for Eskom Power Station

• 240-56227573: GGSS 1201 AC metal enclosed switchgear and control gear for voltage above 1kV up to and including 52kV

• GGSS 0456: Specification for LV Switchgear and controlgear assemblies and associated equipment for voltages up to and including 1000V and 1500V DC (Rev 4)

• GGSS 0386: Requirements for Control and Power Cables Station Standard

15

COURSES ATTENDED

• COURSE 1- MANAGE ENGINEERING ACCOUNTABILITY [MEA]

• COURSE 2– PLANT SAFETY REGULATION

• COURSE 3 - OPERATING REGULATIONS FOR HIGH VOLTAGE SYSTEMS

• COURSE 4 - HYPERWAVE DOCUMENT MANAGEMENT SYSTEMS

21/05/2013 16

OUTSTANDING MODULES

I still need exposure on the following topics:

•Tender Evaluations Process and Criteria

•Contracting strategies

•Procurement Process

•Protection

•Export Systems

•DC Systems

20/05/2013 17

Conclusion

• All the work done, skills/knowledge obtained and experience gained, by Shandukani Vhulondo, in working as an engineer-in-training (EIT)

• The division to which service was rendered to, and where this division fits in the Eskom organisation has been highlighted.

• For each of the projects in which services were rendered, the project objectives, the role and responsibilities of Shandukani Vhulondo and

• The skills and knowledge obtained by Shandukani from working in the project has been presented.

• All the standards and specifications to which compliance is required in the different projects have been highlighted.

• The courses attended during this training period has been highlighted.

• All the standards and specifications to which compliance is required in the different projects have been highlighted

• Attitude is key: It can make difference to our dreams

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Acknowledgement

• I would like to give thanks and appreciation to all those that took their time to help me when I needed help, give advice and answered many question I have asked.

• Etienne du Preez (Coach)

• Dr.Marubini Manyage (Mentor)

• Dyke Munyane

• Tiego Moroaswi

• Vonani Mathebula

• Elekanyani Ndlovu

• Makgatle Lentsoane,

• Tumiso Railo

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27/05/2013 20

Thank you