240-89501275 Medupi Power Station Earthing Lightning ... · Medupi Power Station Earthing & Lightning Protection Maintenance Strategy Unique Identifier: 240-89501275 Revision: 2 CONTROLLED

Strategy Medupi Power Station

Title: Medupi Power Station Earthing & Lightning Protection Maintenance Strategy

Document Identifier: 240-89501275

Alternative Reference Number:

237-160-EE-SG

Area of Applicability: Medupi Power Station

Functional Area: Engineering

Revision: 2

Total Pages: 42

Next Review Date: April 2018

Disclosure Classification:

Controlled Disclosure

Medupi Power Station Earthing & Lightning Protectio n Maintenance Strategy

Unique Identifier: 240-89501275

Revision: 2

Page: 2 of 42

CONTROLLED DISCLOSURE

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

Content Page

1. Introduction .................................................................................................................................................. 4

2. Supporting Clauses ..................................................................................................................................... 4

2.1 Scope ................................................................................................................................................. 4

2.1.1 Purpose .................................................................................................................................. 4

2.1.2 Applicability ............................................................................................................................ 4

2.1.3 Effective date ......................................................................................................................... 4

2.2 References ......................................................................................................................................... 4

2.2.1 Normative ............................................................................................................................... 4

2.2.2 Informative ............................................................................................................................. 5

2.3 Definitions ........................................................................................................................................... 5

2.4 Abbreviations ...................................................................................................................................... 6

2.5 Roles and Responsibilities ................................................................................................................. 6

2.6 Process for Monitoring ....................................................................................................................... 7

2.7 Related/Supporting Documents ......................................................................................................... 7

3. Plant System Overview ............................................................................................................................... 7

3.1 Earthing System Description .............................................................................................................. 7

3.2 System Conductors & Interconnections ............................................................................................. 7

3.3 Earthing & Lightning Installations ....................................................................................................... 8

3.3.1 MV & LV Switchboards and Control Panels/Cubicles ........................................................... 8

3.3.2 Structural steelwork ............................................................................................................... 8

3.3.3 Metal roofs and cladding ........................................................................................................ 8

3.3.4 Ancillary buildings .................................................................................................................. 8

3.3.5 Flue-ducts and support structures ......................................................................................... 8

3.3.6 Storage Vessels ..................................................................................................................... 8

3.3.7 Conveyors .............................................................................................................................. 8

3.3.8 Coal stackers / Reclaimers and Ash Stackers. ...................................................................... 8

3.3.9 Earthing of shiftable (ash) conveyor modules ........................................................................ 9

3.3.10 Earthing of stacker / reclaimer, tripper cars and stackers to rails .......................................... 9

3.3.11 Chimneys ............................................................................................................................... 9

3.4 Maintenance Strategy ........................................................................................................................ 9

3.4.1 Condition Monitoring: Visual Inspections ............................................................................. 10

3.4.2 Condition Monitoring: Tests & Measurements ..................................................................... 10

3.4.3 Documentation and Records ............................................................................................... 11

4. Acceptance ................................................................................................................................................ 12

5. Revisions ................................................................................................................................................... 12

6. Development Team ................................................................................................................................... 12

7. Acknowledgements ................................................................................................................................... 12

Appendix A –FMECA: Earthing & Lightning Protection RBO Spreadsheet ..................................................... 13

Appendix B –Checklist Template: Earthing & Lightning Protection System Inspection ................................... 40



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Appendix C –Checklist Template: Earthing & Lightning Protection System Continuity measurement ............ 41

Appendix D –Checklist Template: Earthing & Lightning Protection System Resistance measurements ........ 42



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1. Introduction

• The Medupi Power Station Earthing and Lightning Protection Systems serves a vital role in ensuring personnel safety and effective operation of plant equipment under normal and fault/lightning conditions.

• Only an effectively maintained earthing system will reliably provide the designed and requisite service as well as meet minimum statutory requirements. This calls for a strategic approach in planning and maintaining the installed system.

2. Supporting Clauses

2.1 Scope The maintenance strategy, as presented in this document applies to the underground earthing network of earth mats and earth rods and to the surface connections of equipment to the earthing network. This strategy is aimed at guaranteeing the integrity of the station wide earthing system to which equipment is connected. Equipment connected to earth includes the following:-

• All Unit and Common Plant electrical and C&I equipment and installations. • All metal mechanical structures and equipment (including air cooled condensers, flue ducts,

vessels, conveyors, piping, towers, and rails). • Civil structures (including chimneys) • Security lightning & Fences. • HV Yard (Actual maintenance work is done by Transmission Division but copies of records

of work is to be maintained at Medupi together with all earthing related records) Specialized earthing arrangements of individual equipment are not covered by this document. Maintenance of internal earthing wiring of equipment, panels, cubicles, boards etc. is to be part of the strategy for that equipment. The boundaries of the earthing system under discussion are the earth mats and the earth terminal points from which equipment is connected.

2.1.1 Purpose This document serves to formally establish an optimal maintenance strategy, based on the analysis of the various sub-systems of the earthing and lightning protection system in order to improve the safety, reliability and availability of the plant as a whole. The proposed maintenance strategy aims to prescribe a plan for “What to be done” and “When to be done”. The plans include all inspection, testing and measurements requirements to obtain reliable information for accurate assessment of the system condition. The information will in turn be used for decisions on the future life cycle management strategy and continual improvement.

2.1.2 Applicability This document shall apply to Medupi Power Station.

2.1.3 Effective date Effective date is the same as the date of authorisation.

2.2 References Parties using this document shall apply the most recent edition of the documents listed in the following paragraphs.

2.2.1 Normative [1] 0.84/1047 Medupi Power Station Earthing Drawings [2] 0.84/21 Medupi Power Station Reticulation Drawing



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[3] 200-11757 Medupi Power Station Earthing & Lightning Protection Standard [4] 240-90354249 Medupi Power Station Earthing & Lightning Protection Spares Strategy

2.2.2 Informative [5] 200-37830 Medupi URS

2.3 Definitions

Term Description

Air Terminals The component of the lightning protection system which is mounted at the highest point and is intended to directly intercept the lightning stroke.

Condition Monitoring

Non-intrusive monitoring carried out to determine the physical condition of plant and equipment.

Continuity The effect one gets when bonding is done between different earth mats or equipment in order to get a low resistive path between the areas.

Corrective Maintenance

The process of restoring plant and equipment which have failed or deteriorated to a state which renders it unable to meet the acceptance criteria required for its application.

Down conductor A conductor that connects an air terminal to an earth terminal.

Earth Mat A mesh of bare copper rods buried in the earth.

Earth spike A conducting rod, normally copper, driven into soil to get a conducting path for fault currents.

Earth Strap/Connection Strap

A conductor intended to be used for potential equalization between metal bodies and the earthing system.

Earth Tail The conductor directly connected to the earth mat/rod that rises above ground to provide the link between equipment or earth bars with the earth mat/rod.

Earth Test Point

A point numbered with a KKS code from which a reading can be taken to determine the status of an Earth mat.

Earthing An intentional electrical connection to the general mass of earth. Earthing Bonding

The connecting together of exposed conductive parts of apparatus, systems and installations to ensure that they are at the same potential.

Earthing conductor

Any conductor, normally copper or aluminium that is the connection between the equipment and the earth mat.

Equipotential bonding The electrical connection putting various exposed conductive parts at an equal potential.

In-service Inspection

All inspection and testing conducted on plant and equipment at regular intervals and prescribed by regulatory and statutory codes or other types of specification throughout its service life.

Inspection Activities, which by means of examination, observation or measurement, determine the conformance of material, parts, components etc., to predetermined specifications and quality requirements.

KKS Coding The approved code assigned by Configuration Management to a specific plant or equipment to identify the plant or equipment for testing, isolation, control and maintenance purposes.

Main Station earth mat

The main portion of the station earth mat, formed by the Boiler and Turbine earth mat grid.

Maintenance A combination of all technical, administrative and managerial actions during the life cycle of an item intended to retain it in, or restore it to, a state in which it can perform the intended or design function.

Maintenance Plan

A structured set of tasks, which include the activities and time scales required to carry out maintenance on equipment. This could be a combination of preventive or predictive maintenance tasks and forms the basis of all PM’s found in SAP for that plant system.



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Term Description Maintenance Strategy

Management method used in order to achieve the maintenance objectives. Furthermore it is the choice of routine maintenance tasks and the timing of those tasks, designed to ensure that an item of equipment continues to fulfil its intended functions.

Preventive Maintenance

Maintenance carried out at predetermined time intervals or according to prescribed criteria and intended to reduce the probability of failure or the degradation of the functioning of an item. Note: The term PM’s is also used in a general sense in Generation to describe the planned activities located in SAP.

Station earth mat The earth mat formed by interconnecting all earth mats on the Power Station.

Step potential The difference in surface potential experienced by a person bridging a distance of 1 m with his feet without contacting any other grounded object (IEEE Standard 80-1987),

Test Triangle Visual identification of an earth test point with its own unique KKS code. Testing All activities required to determine the actual performance or condition of an item.

Touch voltage The potential generated when fault currents flow through an electrical system. Note that with a lower resistance/impedance in the earthing system, the lower is the touch potential.

Trench earth An earth electrode consisting of a length of bare conductor buried in the earth at a uniform depth.

2.4 Abbreviations

Abbreviation Explanation C&I Control and Instrumentation Department EMD Electrical Maintenance Department Floc Functional Location Code (KKS) FMECA Failure Mode Effects and Criticality Analysis GO General Overhaul IR Interim Repair LV Low Voltage MV Medium Voltage O&M Operating and Maintenance OEM Original Equipment Manufacturer OHSACT Occupational Health and Safety Act RBO Reliability Basis Optimisation RTF Run to Failure SAP PM Plant Maintenance module in SAP SE System Engineer V Volts VA Volt-Ampere

2.5 Roles and Responsibilities

a) Electrical Engineering Department

• Compile and updating of the maintenance strategy • Ensure all maintenance activities are performed as per maintenance strategy

requirements. • Ensure good upkeep of the system including long term plant health • Provide technical evaluation of equipment and material • Monitor and optimised plant performance



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b) Electrical Maintenance Department

• Plan and schedule electrical maintenance activities. • Execution of maintenance tasks during the scheduled maintenance period • Supervision of maintenance activities performed as per maintenance strategy

requirements

c) Protection and Metering Department

• To ensure all protection activities are performed according to the maintenance requirements.

d) Performance and Testing Department

• To perform all relevant tests and measurements.

2.6 Process for Monitoring

Follow auditable materials management processes.

2.7 Related/Supporting Documents

240-90354249 Medupi Power Station Earthing & Lightning Protection Spares Strategy: Rev 2

3. Plant System Overview

3.1 Earthing System Description

a) The Medupi Power Station earthing and lightning protection system consists of an underground network of interconnected earth mats buried at a depth of 1000mm (one of which is the Main Station Earth Mat) and earth electrodes. Connected to this underground network and rising above ground are earth-tails and lightning conducting down-comers to which all electrical equipment and structures are connected to provide the earthing and lightning protection requirements.

b) Equipment and structures connected to earth in this manner includes metal conduits, metal cable racks, cable armouring, junction boxes, panels, motor frames, transformers tanks, switchgear enclosures, metal enclosures for motor controllers, frames, cubicles, main support structures, reinforcement steels, roofs, metal wall cladding gutters, vessels etc.

3.2 System Conductors & Interconnections

a) The station earth mats consists of 10 mm diameter black copper rod (except in the transformer bay where two copper rods run in parallel). The rods are brazed or exothermically welded. All other earth mats are connected to the main station earth mat by at least two connections of 50 X 3 mm flat copper bar. Flat copper bars or 10 mm diameter copper rods for earth tails are silver soldered or welded exothermically onto the copper rod or embedded reinforcing bars where applicable.

b) The equipment or its earth bar is connected to the earth tails by means of coppers straps of suitable sizes. These connections are made by copper clamps or by brazing. Galvanized steel straps and bare copper cables are in use in some applications. Where earth continuity conductors are provided as a separate core in cables this earth core is connected to the earth bar of the supply point and to the earthing point provided the for the equipment.

c) To meet the EMC requirements of equipment like variable speed drives, shielded symmetrical cable types are in use.



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3.3 Earthing & Lightning Installations

The earthing and lightning protection network spans across the whole power station electrical power reticulation network and on all metal structures. Suitable installation arrangements are in place for the specific equipment in particular areas as discussed below.

3.3.1 MV & LV Switchboards and Control Panels/Cubic les Switchboards, control panels and cubicles have an earth bar running over the length of the board. These earth bars are connected to the earth mat once for single panels and at least on each end for larger boards. Continuous earthing is provided and installed on all equipment constituting the electrical network. I.e. Power & Control Cables, Cable Racking, Distribution Boards, Junction Boxes and Cubicles. All electrical and C&I equipment is connected to earth points as per its design requirements.

3.3.2 Structural steelwork All station steelwork structures are connected to the earth mat. The boiler and turbine house main building columns are connected to the station earth mat. Steel columns supporting equipment such as the bag filter houses, inclined conveyors, etc. are connected to the station earth mat.

3.3.3 Metal roofs and cladding Metal roofs or steel trusses not in direct contact with building steelwork are connected to the earth mat by down conductors at diagonally opposite points of the building.

3.3.4 Ancillary buildings These buildings include electrical substations, water treatment plant, auxiliary cooling system, workshop and stores, administration buildings, etc. The main structural steelwork of all the ancillary buildings is connected to their relevant earth mats or earth rods. The earth mat is connected to the main station earth to ensure continuity. All major equipment in the building are connected to a main copper earth strap that is connected to the earth mat.

3.3.5 Flue-ducts and support structures The flue gas ducts are provided with an earthing system. Earth rods are buried along both sides of the support structures for the flue-ducts. These rods are connected to the earth mat surrounding the chimneys and to the earth mat of the gas cleaning plant. All steel structures supporting the flue-ducts are connected to these earth rods.

3.3.6 Storage Vessels All storage tanks are bonded to the earth mat with one connection for small tanks and two for bigger tanks.

3.3.7 Conveyors Fixed conveyor structures are bonded to the earthing system at each end. The shiftable conveyor structures are bonded at head and tail sides with two flexible connections of at least 70 mm2 to the head station and the feeding conveyor respectively.

3.3.8 Coal stackers / Reclaimers and Ash Stackers.

3.3.8.1 Rails: Longitudinal bonding Electrical bonds are secured across rail joints by suitable conductors connected across the joint. At head and tail end, the rails are bonded to the earthing system of transfer houses by two 10 mm diameter copper rods.



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3.3.8.2 Rails: Cross bonding Cross connections between the two rails are established at distances of 50m by flat copper bar or PVC insulated conductors of 70 mm2 cross sectional area. Hot dip galvanized steel strap of not less than 50 x 4 mm is alternatively used.

3.3.8.3 Rails: Connections to earth On rails run on concrete sleepers, earth spikes are installed at distances of ± 50 m along the rails on alternative sides. Where rails are continuously welded electrical bonding has been done at the ends only to connect to the earth mats of transfer houses etc.

3.3.9 Earthing of shiftable (ash) conveyor modules The conveyors are connected with at least one earth conductor installed with sufficient slack to allow for shifting of the conveyor modules.

3.3.10 Earthing of stacker / reclaimer, tripper car s and stackers to rails Earthing continuity is provided by suitable conductors across swivel or other joints e.g. bogies etc. Special earthing provision is in place for:-

• On-board equipment • Cross bonding of ash stackers and link conveyors to tripper cars

3.3.11 Chimneys a) Chimneys are provided with an earthing and lightning protection system. The system

comprises of air terminals, down conductors and an earth mat in accordance with the chimney earthing drawing. Air terminal components are bonded to the chimney down conductors.

b) The earth mat electrode of 10 mm diameter copper rod surrounds the chimney with inspection pits located at intervals as indicated on the relevant drawings. The aircraft warning lights are connected to the earthing system.

3.4 Maintenance Strategy

a) The Medupi Power Station Earthing and Lightning Protection System consists of an underground network of interconnected earth mats buried at a depth of 1000mm (one of which is the Main Station Earth Mat) and earth electrodes. Connected to this underground network and rising above ground are earth-tails and lightning conducting down-comers to which all electrical equipment and structures are connected to provide the earthing and lightning protection requirements.

b) Equipment and structures connected to earth in this manner includes metal conduits, metal cable racks, cable armouring, junction boxes, panels, motor frames, transformers tanks, switchgear enclosures, metal enclosures for motor controllers, frames, cubicles, main support structures, reinforcement steels, roofs, metal wall cladding gutters, vessels etc.

c) The strategy that has been adopted for the maintenance of the earthing and lightning protection systems is premised on the FMECA (Appendix i) done for the system. It is noted that the earthing system is a network that spans across the whole station processes and has a significant number of similar points of weakness and of testing and measurement.



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d) Preventive and Corrective maintenance measures are to be implemented to curtail the deterioration of the effectiveness of the earthing system and to maintain its integrity. The system health is to be monitored qualitatively through inspections and quantitatively through test and measurements. Corrective action is to be taken for any signs of deterioration and defects. Records and documentation pertaining to the Earthing and Lightning System are to be maintained and be readily retrievable. For this purpose, the earthing and lightning protection system is subdivided into Functional Locations as per installed earth mats.

e) Common failures on the earthing systems are corrosion, lightning strike, electrical faults, mechanical damage, poor workmanship and copper theft. For each Functional Location (Appendix ii), the following will be done:

• Regular Visual Inspections (including downstream equipment and plant area) • Regular Tests and Measurements • Repair and corrective action

f) Use of earthing drawings will ensure all points are attended to. Suitable test and measuring equipment specific for Earthing Tests is to be used.

3.4.1 Condition Monitoring: Visual Inspections a) Regular visual inspections must be carried out on all the earthed equipment and a report

generated in which the following is mentioned: • Signs of corrosion, • Evidence of loose or otherwise faulty connections, • Unnecessary bending of earth rods (sharp curves < 90°), • Unearthed electrical equipment, • Unearthed structures and • Any signs that the earthing copper may have been stolen. • Remarks on general health of the systems and any corrective action taken or to be taken.

b) A complete visual inspection should be performed at frequencies as shown in the FMECA results

3.4.2 Condition Monitoring: Tests & Measurements a) It is of importance to carry out check measurements immediately after installation and

commissioning and recording the results. There after periodical measurements of continuity and resistivity to true earth must be carried out and recorded as well. These allow trending and comparison with baseline measurements taken at commissioning and so allow the recognition of changes and for counter measures if values deteriorate.

b) Tests should be conducted after any major electrical fault. It is vital to ensure that the earth mat of any new installation is correctly bonded to the existing earth mat.

c) All earth connections are important but special attention should be given to: • Earth connections of generator transformer star points, surge arresters, CVTs, NECs or

earthing resistors and, • Bonding between the secondary circuit star points of VTs and CTs, which are normally

earthed at different locations. d) Besides comparing the new and the old test results, comparisons can also be made between

the resistances between similar parts on different Units. Interpretation of these measurements of continuity and resistance to true earth give an indication of the quality and expected life of the earthing installation.

e) These tests are performed to prove that the plant is properly earthed. The record keeping of the tests are important. The measurement and inspection report numbers should be reflected on the maintenance (PM) feedback.



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3.4.2.1 Earthing Triangles a) The earth tail reference point system shall be used to enable the repeating of the continuity

tests. The reference points are the earth mat tails (and major plant e.g. generator, chimney etc.), marked in the plant with green triangles, with a KKS number that corresponds with the number on the drawing. These readings can be taken to determine the status of an earth mat. Continuity measurements are then performed between the triangles and between the equipment and the triangles. This can be repeated for the routine tests.

b) The purpose of having the test points is to keep continuity in the testing of the earth mats over the life span of the station. They provide a defined point to test from and test to. The same points are used over the test periods

3.4.2.2 Resistance Measurements a) This test gives an indication what the resistance to earth is. Earth resistance tests should be

carried out before the rain season starts; when the soil is dry and ground resistance is high (this is the worst case). The resistance tests are carried out with respect to reference earth triangles.

b) The earth tails are fixed points with recorded earth resistance readings. The readings can be compared over years to get an indication if the resistance to earth stays stable. It is important to record environmental information regarding time of the year and what the rainfall pattern was during the time of measurements, because this will influence readings. The resistance readings should be smaller than 0.14 Ω to keep the touch-potential smaller or equal to 165 V.

3.4.2.3 Continuity measurements This test gives an indication of how good the connection between any two earthing points is. Continuity readings must be 12milli-ohm and below. These tests are carried out every twenty four months on all the major earthing equipment on the power station.

3.4.3 Documentation and Records

3.4.3.1 Design Standards Maintenance personnel are to be familiar with the Medupi Power Station Earthing and lightning Protection Standard. The standard is the basis for any technical specifications and modifications to the plant.

3.4.3.2 Drawings The Power Station earthing layout drawings are a vital maintenance check reference and should be kept up to date to reflect as built status of the installed plant. Reference Drawings are indicated under the FMECA spread-sheet as well as in the Appendix.

3.4.3.3 Scheduled Maintenance Plan Maintenance activities (PM’s) as identified in the FMECA are generated and issued to the maintenance personnel to perform inspections and tests. Scheduling is done per functional location and through use of the standard check lists.

3.4.3.4 Reports Feedback reports for the inspections and tests are generated and kept in the form of completed checklists. Records for inspections and tests done for the HV Yard should be obtained and kept as well.



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4. Acceptance

This document has been seen and accepted by: Name Designation Prince Khumalo Engineering Group Manager Pamela Pretorius Maintenance Group Manager Verwey Fourie Acting Electrical Engineering Manager Portia Lutumbu Electrical Maintenance Manager Seshibe Makgato Design & Specification Manager Lennox Dukashe Chief Technologist Engineering

5. Revisions

Date Rev. Compiler Remarks Sept 2013 1 M. Mukwevho Revision 1 Feb 2016 2 M. Mukwevho Due for review, document format changed

6. Development Team

The following people were involved in the development of this document: Name Designation Verwey Fourie Acting Electrical manager

Mbavhalelo Mukwevho Electrical Engineer

7. Acknowledgements

Special thank you to the following people: • Thamsanqa Buthelezi – System Engineer • Lennox Dukashe – Chief Technologist Engineering

Medupi Power Station Earthing & Lightning Protectio n Maintenance Strategy Unique Identifier: 240-89501275

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Appendix A –FMECA: Earthing & Lightning Protection RBO Spreadsheet

Medupi Power Station Earthing & Lightning Protection FMECA

Plant Equipment Functional

Location

(KKS Code)

Components (functional

location description)

Type Functional

Importance

(C/NC/RTF)

Parts (that

could fail)

Functional

Failure

Failure

Mode

Strategy Dept. RBO

Frequency

(W/M/Y)

Power

Unit

Run or

Outage

Remarks Doc

Requirements

WATER TREATMENT PLANT

Earthing & Lightning Protection Equipment

00BAW01 DRAWING 0.84/1047-SHEET 1

Copper Rods; Copper Flat Bars; Copper Cables; Galvanized Steel straps

C

Earth Tails; Earth Spikes; Earth Connection Straps; Joints; Welds

Loss of Earthing Continuity, Loss of Bonding; Loss of Safety Protection;

Corrosion; Loose Connection; Mechanical Damage; Copper Theft Cracking, Bending, Unearthed equipment

Visual inspection:

EMD 6-monthly

Run Inspection Check List

Earth Continuity Tests

EMD 18-months

Earth Continuity Check List

Earth Resistance Tests

EMD 18-months

Earth Resistance Check List

WORKSHOP AND STORES


Visual inspection:

EMD 6-monthly



EMD 18-months



EMD 18-months


UNIT 1 BLOWER HOUSE AND BOILER 1


Visual inspection:

EMD 12-monthly



EMD 18-months



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Location

(KKS Code)



Type Functional

Importance

(C/NC/RTF)

Parts (that

could fail)

Functional

Failure

Failure

Mode

Strategy Dept. RBO

Frequency

(W/M/Y)

Power

Unit

Run or

Outage

Remarks Doc

Requirements


EMD 18-months


UNIT 1 ACC AND TURBINE AREAS




C




Visual inspection:

EMD 12-monthly



EMD 18-months



EMD 18-months




Visual inspection:

EMD 12-monthly



EMD 18-months



EMD 18-months


UNIT 2 ACC AND TURBINE AREAS 2


Visual inspection:

EMD 12-monthly



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Location

(KKS Code)



Type Functional

Importance

(C/NC/RTF)

Parts (that

could fail)

Functional

Failure

Failure

Mode

Strategy Dept. RBO

Frequency

(W/M/Y)

Power

Unit

Run or

Outage

Remarks Doc

Requirements


EMD 18-months



EMD 18-months






C




Visual inspection:

EMD 12-monthly



EMD 18-months



EMD 18-months




Visual inspection:

EMD 126-monthly



EMD 18-months



EMD 18-months



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Location

(KKS Code)



Type Functional

Importance

(C/NC/RTF)

Parts (that

could fail)

Functional

Failure

Failure

Mode

Strategy Dept. RBO

Frequency

(W/M/Y)

Power

Unit

Run or

Outage

Remarks Doc

Requirements

BLOWER HOUSE AND BOILER 4


Visual inspection:

EMD 12-monthly



EMD 18-months



EMD 18-months


ACC AND TURBINE AREAS 4




C




Visual inspection:

EMD 12-monthly



EMD 18-months



EMD 18-months




Visual inspection:

EMD 12-monthly



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Location

(KKS Code)



Type Functional

Importance

(C/NC/RTF)

Parts (that

could fail)

Functional

Failure

Failure

Mode

Strategy Dept. RBO

Frequency

(W/M/Y)

Power

Unit

Run or

Outage

Remarks Doc

Requirements


EMD 18-months



EMD 18-months




Visual inspection:

EMD 12-monthly



EMD 18-months



EMD 18-months






C




Visual inspection:

EMD 12-monthly



EMD 18-months



EMD 18-months



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Location

(KKS Code)



Type Functional

Importance

(C/NC/RTF)

Parts (that

could fail)

Functional

Failure

Failure

Mode

Strategy Dept. RBO

Frequency

(W/M/Y)

Power

Unit

Run or

Outage

Remarks Doc

Requirements



Visual inspection:

EMD 12-monthly



EMD 18-months



EMD 18-months


AUXILIARY COOLING


Visual inspection:

EMD 12-monthly



EMD 18-months



EMD 18-months


BULK FUEL OIL PLANT PUMP HOUSE BUILDING




C



Corrosion; Loose Connection; Mechanical Damage; Copper Theft Cracking, Bending,

Visual inspection:

EMD 6-monthly



EMD 18-months



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Location

(KKS Code)



Type Functional

Importance

(C/NC/RTF)

Parts (that

could fail)

Functional

Failure

Failure

Mode

Strategy Dept. RBO

Frequency

(W/M/Y)

Power

Unit

Run or

Outage

Remarks Doc

Requirements

Unearthed equipment


EMD 18-months


UNIT 1 - 3AUXILIARY BOILER


Visual inspection:

EMD 12-monthly



EMD 18-months



EMD 18-months


AUXILIARY BAY 00BAW05 DRAWING 0.84/1047-SHEET 19

Visual inspection:

EMD 12-monthly



EMD 18-months



EMD 18-months


UNIT 1 - 4 TURBINE HALL

Earthing & Lightning Protection

TBA DRAWING 0.84/1047-SHEET 20

Copper Rods; Copper Flat Bars; Copper Cables;

C

Earth Tails; Earth Spikes; Earth

Loss of Earthing Continuity, Loss of

Corrosion; Loose Connection; Mechanical

Visual inspection:

EMD 12-monthly



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Location

(KKS Code)



Type Functional

Importance

(C/NC/RTF)

Parts (that

could fail)

Functional

Failure

Failure

Mode

Strategy Dept. RBO

Frequency

(W/M/Y)

Power

Unit

Run or

Outage

Remarks Doc

Requirements

Equipment

Galvanized Steel straps

Connection Straps; Joints; Welds

Bonding; Loss of Safety Protection;

Damage; Copper Theft Cracking, Bending, Unearthed equipment


EMD 18-months



EMD 18-months


CONSTRUCTION OFFICE H BLOCK


Visual inspection:

EMD 6-monthly



EMD 18-months



EMD 18-months


UNIT 1 TO 5 STG GROUNDING CONNECTION


Visual inspection:

EMD 12-monthly



EMD 18-months



EMD 18-months



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Location

(KKS Code)



Type Functional

Importance

(C/NC/RTF)

Parts (that

could fail)

Functional

Failure

Failure

Mode

Strategy Dept. RBO

Frequency

(W/M/Y)

Power

Unit

Run or

Outage

Remarks Doc

Requirements

WATER TREATMENT PLANT CIVIL GUIDE




C




Visual inspection:

EMD 6-monthly



EMD 18-months



EMD 18-months


UNIT 6 TRANSVERSE ASH CONVERYOR FOUNDATION


Visual inspection:

EMD 6-monthly



EMD 18-months



EMD 18-months


WATER TREATMENT PLANT ORGANIC SCAVENGERS


Visual inspection:

EMD 6-monthly



EMD 18-months



Revision: 2

Page: 22 of 42





Location

(KKS Code)



Type Functional

Importance

(C/NC/RTF)

Parts (that

could fail)

Functional

Failure

Failure

Mode

Strategy Dept. RBO

Frequency

(W/M/Y)

Power

Unit

Run or

Outage

Remarks Doc

Requirements


EMD 18-months


WATER TREATMENT PLANT CHEMICAL DOSING




C




Visual inspection:

EMD 6-monthly



EMD 18-months



EMD 18-months


WATER TREATMENT PLANT SULPHURIC ACID AND CAUSTIC SODA


Visual inspection:

EMD 6-monthly



EMD 18-months



EMD 18-months


WATER TREATMENT PLANT AMMONIA


Visual inspection:

EMD 6-monthly



Revision: 2

Page: 23 of 42





Location

(KKS Code)



Type Functional

Importance

(C/NC/RTF)

Parts (that

could fail)

Functional

Failure

Failure

Mode

Strategy Dept. RBO

Frequency

(W/M/Y)

Power

Unit

Run or

Outage

Remarks Doc

Requirements

TANKS Earth Continuity Tests

EMD 18-months



EMD 18-months


WATER TREATMENT PLANT CHLORINATION BUILDING




C




Visual inspection:

EMD 6-monthly



EMD 18-months



EMD 18-months


WATER TREATMENT PLANT BRINE MAKE UP TANK


Visual inspection:

EMD 6-monthly



EMD 18-months



EMD 18-months



Revision: 2

Page: 24 of 42





Location

(KKS Code)



Type Functional

Importance

(C/NC/RTF)

Parts (that

could fail)

Functional

Failure

Failure

Mode

Strategy Dept. RBO

Frequency

(W/M/Y)

Power

Unit

Run or

Outage

Remarks Doc

Requirements

WATER TREATMENT PLANT CLARIFIER STRUCTRE


Visual inspection:

EMD 6-monthly



EMD 18-months



EMD 18-months


WATER TREATMENT PLANT CLARIFIER




C




Visual inspection:

EMD 6-monthly



EMD 18-months



EMD 18-months


WATER TREATMENT PLANT PSA PLANT BUILDING


Visual inspection:

EMD 6-monthly



EMD 18-months



Revision: 2

Page: 25 of 42





Location

(KKS Code)



Type Functional

Importance

(C/NC/RTF)

Parts (that

could fail)

Functional

Failure

Failure

Mode

Strategy Dept. RBO

Frequency

(W/M/Y)

Power

Unit

Run or

Outage

Remarks Doc

Requirements


EMD 18-months


WATER TREATMENT PLANT BLOWER AND VACUM PUMP BUILDING


Visual inspection:

EMD 6-monthly



EMD 18-months



EMD 18-months


WATER TREATMENT PLANT NEUTRALIZATION SUMP AND INTERCONNECTING




C




Visual inspection:

EMD 6-monthly



EMD 18-months



EMD 18-months


WATER TREATMENT PLANT PUMP PLINTHS AND


Visual inspection:

EMD 6-monthly



Revision: 2

Page: 26 of 42





Location

(KKS Code)



Type Functional

Importance

(C/NC/RTF)

Parts (that

could fail)

Functional

Failure

Failure

Mode

Strategy Dept. RBO

Frequency

(W/M/Y)

Power

Unit

Run or

Outage

Remarks Doc

Requirements

TRENCH


EMD 18-months



EMD 18-months


WATER TREATMENT PLANT SUBSTATION


Visual inspection:

EMD 6-monthly



EMD 18-months



EMD 18-months


MINI SUBSTATION EARTHMAT




C




Visual inspection:

EMD 6-monthly



EMD 18-months



EMD 18-months



Revision: 2

Page: 27 of 42





Location

(KKS Code)



Type Functional

Importance

(C/NC/RTF)

Parts (that

could fail)

Functional

Failure

Failure

Mode

Strategy Dept. RBO

Frequency

(W/M/Y)

Power

Unit

Run or

Outage

Remarks Doc

Requirements

UNIT 1 - 6 LIFT STRUCTURE LIGHTING PROTECION LAYOUT


Visual inspection:

EMD 12-monthly



EMD 18-months



EMD 18-months


BULK FUEL OIL 00BAW22 DRAWING 0.84/1047-SHEET 40

Visual inspection:

EMD 6-monthly



EMD 18-months



EMD 18-months


ASH CONDITIONING PLANT




C



Corrosion; Loose Connection; Mechanical Damage; Copper Theft Cracking, Bending,

Visual inspection:

EMD 6-monthly



EMD 18-months



Revision: 2

Page: 28 of 42





Location

(KKS Code)



Type Functional

Importance

(C/NC/RTF)

Parts (that

could fail)

Functional

Failure

Failure

Mode

Strategy Dept. RBO

Frequency

(W/M/Y)

Power

Unit

Run or

Outage

Remarks Doc

Requirements

Unearthed equipment


EMD 18-months


CHILLED PLANT SOUTH


Visual inspection:

EMD 6-monthly



EMD 18-months



EMD 18-months


BULK OIL FUEL ROA THANER OFF LOADING


Visual inspection:

EMD 6-monthly



EMD 18-months



EMD 18-months


CLEAN AND DIRTY WATER PUMP STATION



Copper Rods; Copper Flat Bars; Copper Cables;

C




Visual inspection:

EMD 6-monthly



Revision: 2

Page: 29 of 42





Location

(KKS Code)



Type Functional

Importance

(C/NC/RTF)

Parts (that

could fail)

Functional

Failure

Failure

Mode

Strategy Dept. RBO

Frequency

(W/M/Y)

Power

Unit

Run or

Outage

Remarks Doc

Requirements

Equipment






EMD 18-months



EMD 18-months


FIRE PUMP HOUSE


Visual inspection:

EMD 6-monthly



EMD 18-months



EMD 18-months


COAL STOCK YARD PUMP STATION

N/A DRAWING 0.84/1047-SHEET 47

Visual inspection:

EMD 6-monthly



EMD 18-months



EMD 18-months



Revision: 2

Page: 30 of 42





Location

(KKS Code)



Type Functional

Importance

(C/NC/RTF)

Parts (that

could fail)

Functional

Failure

Failure

Mode

Strategy Dept. RBO

Frequency

(W/M/Y)

Power

Unit

Run or

Outage

Remarks Doc

Requirements

INCLINE CONVEYOR COAL


N/A DRAWING 0.84/1047-SHEET 48


C




Visual inspection:

EMD 6-monthly



EMD 18-months



EMD 18-months


UNIT 6 GENERATOR AND UNIT TRANSFORMERS


Visual inspection:

EMD 12-monthly



EMD 18-months



EMD 18-months


FABRIC FILTER AND BLOWER HOUSE SUBSTATION


Visual inspection:

EMD 6-monthly



EMD 18-months



Revision: 2

Page: 31 of 42





Location

(KKS Code)



Type Functional

Importance

(C/NC/RTF)

Parts (that

could fail)

Functional

Failure

Failure

Mode

Strategy Dept. RBO

Frequency

(W/M/Y)

Power

Unit

Run or

Outage

Remarks Doc

Requirements


EMD 18-months


UNIT 1 - 6 CPP Earthing & Lightning Protection Equipment



C




Visual inspection:

EMD 12-monthly



EMD 18-months



EMD 18-months


LP GAS TANK 00BAW25 DRAWING 0.84/1047-SHEET 54

Visual inspection:

EMD 6-monthly



EMD 18-months



EMD 18-months


WATER TREATMENT


Visual inspection:

EMD 6-monthly



Revision: 2

Page: 32 of 42





Location

(KKS Code)



Type Functional

Importance

(C/NC/RTF)

Parts (that

could fail)

Functional

Failure

Failure

Mode

Strategy Dept. RBO

Frequency

(W/M/Y)

Power

Unit

Run or

Outage

Remarks Doc

Requirements


EMD 18-months



EMD 18-months


LABORATORY Earthing & Lightning Protection Equipment



C




Visual inspection:

EMD 6-monthly



EMD 18-months



EMD 18-months


SSB 01BAW08 DRAWING 0.84/12299-SHEET 3

Visual inspection:

EMD 6-monthly



EMD 18-months



EMD 18-months



Revision: 2

Page: 33 of 42





Location

(KKS Code)



Type Functional

Importance

(C/NC/RTF)

Parts (that

could fail)

Functional

Failure

Failure

Mode

Strategy Dept. RBO

Frequency

(W/M/Y)

Power

Unit

Run or

Outage

Remarks Doc

Requirements

UNIT 1-6 BOILER HOUSE LEVEL +0,000


Visual inspection:

EMD 12-monthly



EMD 18-months



EMD 18-months


UNIT 1-6 BOILER AREA EARHTMAT FABRIC FILTER PLANT




C




Visual inspection:

EMD 6-monthly



EMD 18-months



EMD 18-months


UNIT 1-6 ID FAN TBA DRAWING 0.84/9332-SHEET 3

Visual inspection:

EMD 12-monthly



EMD 18-months



Revision: 2

Page: 34 of 42





Location

(KKS Code)



Type Functional

Importance

(C/NC/RTF)

Parts (that

could fail)

Functional

Failure

Failure

Mode

Strategy Dept. RBO

Frequency

(W/M/Y)

Power

Unit

Run or

Outage

Remarks Doc

Requirements


EMD 18-months


ID FAN AND FFP AREA LEVEL +0,000


Visual inspection:

EMD 12-monthly



EMD 18-months



EMD 18-months


UNIT 5 UHQ- FABRIC FILTER PLANT ID FAN FOUNDATION




C




Visual inspection:

EMD 6-monthly



EMD 18-months



EMD 18-months


COAL STOCK YARD SOUTH SUBSTATION


Visual inspection:

EMD 6-monthly



Revision: 2

Page: 35 of 42





Location

(KKS Code)



Type Functional

Importance

(C/NC/RTF)

Parts (that

could fail)

Functional

Failure

Failure

Mode

Strategy Dept. RBO

Frequency

(W/M/Y)

Power

Unit

Run or

Outage

Remarks Doc

Requirements


EMD 18-months



EMD 18-months


COAL STOCK YARD NORTH SUBSTATION


Visual inspection:

EMD 6-monthly



EMD 18-months



EMD 18-months


COAL PLANT SUBSTATION




C




Visual inspection:

EMD 6-monthly



EMD 18-months



EMD 18-months



Revision: 2

Page: 36 of 42





Location

(KKS Code)



Type Functional

Importance

(C/NC/RTF)

Parts (that

could fail)

Functional

Failure

Failure

Mode

Strategy Dept. RBO

Frequency

(W/M/Y)

Power

Unit

Run or

Outage

Remarks Doc

Requirements

COAL SILO SUBSTATION


Visual inspection:

EMD 6-monthly



EMD 18-months



EMD 18-months


COMPRESS HOUSE SOUTH

00BAW27 TBA Visual inspection:

EMD 6-monthly



EMD 18-months



EMD 18-months


COMPRESS HOUSE NORTH


01BAW27 TBA Copper Rods; Copper Flat Bars; Copper Cables; Galvanized Steel straps

C

Earth Tails; Earth Spikes; Earth Connection Straps; Joints;

Loss of Earthing Continuity, Loss of Bonding; Loss of Safety

Corrosion; Loose Connection; Mechanical Damage; Copper Theft

Visual inspection:

EMD 6-monthly



EMD 18-months



Revision: 2

Page: 37 of 42





Location

(KKS Code)



Type Functional

Importance

(C/NC/RTF)

Parts (that

could fail)

Functional

Failure

Failure

Mode

Strategy Dept. RBO

Frequency

(W/M/Y)

Power

Unit

Run or

Outage

Remarks Doc

Requirements

Welds

Protection;

Cracking, Bending, Unearthed equipment


EMD 18-months


COMPRESS HOUSE SOUTH SUBSTATION


EMD 6-monthly



EMD 18-months



EMD 18-months


COMPRESS HOUSE NORTH SUBSTATION


EMD 6-monthly



EMD 18-months



EMD 18-months


ACCESS CONTROL BUILDING


00BAW28 TBA Copper Rods; Copper Flat Bars; Copper Cables;

C




Visual inspection:

EMD 6-monthly



Revision: 2

Page: 38 of 42





Location

(KKS Code)



Type Functional

Importance

(C/NC/RTF)

Parts (that

could fail)

Functional

Failure

Failure

Mode

Strategy Dept. RBO

Frequency

(W/M/Y)

Power

Unit

Run or

Outage

Remarks Doc

Requirements

Equipment






EMD 18-months



EMD 18-months


SUBSTATION WEST


EMD 6-monthly



EMD 18-months



EMD 18-months


SUBSTATION NORTH


EMD 6-monthly



EMD 18-months



EMD 18-months



Revision: 2

Page: 39 of 42





Location

(KKS Code)



Type Functional

Importance

(C/NC/RTF)

Parts (that

could fail)

Functional

Failure

Failure

Mode

Strategy Dept. RBO

Frequency

(W/M/Y)

Power

Unit

Run or

Outage

Remarks Doc

Requirements

IT AND TELECOMMUNICATIONS


00BAW31 TBA Copper Rods; Copper Flat Bars; Copper Cables; Galvanized Steel straps

C




Visual inspection:

EMD 6-monthly



EMD 18-months



EMD 18-months


ASH DUMP SUBSTATION


EMD 6-monthly



EMD 18-months



EMD 18-months




Revision: 2

Page: 40 of 42



Appendix B –Checklist Template: Earthing & Lightnin g Protection System Inspection

EARTHING SYSTEM INSPECTION

FUNCTIONAL LOCATION:

EARTHING LAYOUT DRAWING NO.:

DATE OF INSPECTION:

INSPECTION DONE BY:

FACTORS TO INSPECT FOR

Corrosion, Pitting,

Mechanical damage,

Copper theft,

Unearthed points,

Loose or faulty

Connections etc.

ITEM EARTHING POINT SIGNS OF DETERIORATION REMARKS

YES NO

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18



Revision: 2

Page: 41 of 42



Appendix C –Checklist Template: Earthing & Lightning Protection System Continuity measurement

EARTHING CONTINUITY

MEASUREMENTS


EARTHING LAYOUT

DRAWING NO.:

DATE OF INSPECTION:

INSPECTION DONE BY:

DETAILS OF MEASURING

EQUIPMENT

ITEM EARTHING POINT REFERENCE

POINT

CONTINUITY READING :

(Expected reading < 12mΩ)

REMARKS

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16



Revision: 2

Page: 42 of 42



Appendix D –Checklist Template: Earthing & Lightnin g Protection System Resistance measurements

EARTHING RESISTANCE

MEASUREMENTS


EARTHING LAYOUT

DRAWING NO.:

DATE OF INSPECTION:

INSPECTION DONE BY:

DETAILS OF MEASURING

EQUIPMENT

ITEM REFERENCE POINT EARTH RESISTANCE (Ω):

(Expected reading < 0.14Ω)

REMARKS

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17