ESKOM COPYRIGHT PROTECTED

B Morrison / November 2010 / Rev 0

TASK MANUAL

Document Classification: Controlled Disclosure
Title:
Distribution Task Manual Part 11:
CIRCUIT-BREAKER: SIEMENS,
TYPE: 3AP1-FG, 3AP1-F1 AND
3AP1-DT, MECHANISM: FA-2,
RATINGS: 72.5kV-300kV; 4000A;
40-63kA
Unique Identifier: 34-799
Document Type: DMN
Revision: 0
Published date: NOVEMBER 2010
Total pages: 28
Review date: NOVEMBER 2015

COMPILED BY APPROVED BY FUNCTIONAL RESP AUTHORISED BY

_ _ _ _ _ _ _ _
A PERSADH

_ _ _ _ _ _ _ _
M SEYFFERT

_ _ _ _ _ _ _ _
C SMITH

_ _ _ _ _ _ _ _
MN BAILEY
Senior Advisor Maintenance Strategy
WG Chairperson
for TESCOD CMDT for MD (Dx)
DATE: DATE: DATE: DATE:
Content
Page
Foreword .......................................................................................................................................................... 2
Introduction ...................................................................................................................................................... 3
1 Scope ...................................................................................................................................................... 3
2 Normative references .............................................................................................................................. 3
2.1 Normative References ........................................................................................................................ 3
2.2 Informative .......................................................................................................................................... 4
3 Definitions and abbreviations .................................................................................................................. 4
3.1 Definitions ........................................................................................................................................... 4
3.2 Abbreviations ...................................................................................................................................... 4
4 Requirements .......................................................................................................................................... 4
4.1 Responsibilities ................................................................................................................................... 4
4.2 First and second line maintenance ..................................................................................................... 5
4.3 Specialist maintenance ....................................................................................................................... 5
4.4 Testing .............................................................................................................................................. 20
5 Related/Supporting Documents ............................................................................................................ 21
5.1 Related Documents .......................................................................................................................... 21
5.2 Forms and Records .......................................................................................................................... 21
6 Spares ................................................................................................................................................... 21
Annex A - Circuit-breaker / Recloser report .................................................................................................. 22
Annex B Impact Assessment ...................................................................................................................... 25

DOCUMENT CLASSIFICATION: CONTROLLED DISCLOSURE
CIRCUIT-BREAKER: SIEMENS, TYPE: 3AP1-FG,
3AP1-F1 AND 3AP1-DT, MECHANISM: FA-2,
RATINGS: 72.5kV-300kV; 4000A; 40-63kA
Unique Identifier: 34-799
Type: DMN
Revision: 0
Page: 2 of 28
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to ensure it is in line with the authorised version on the WEB.
Foreword
This task manual supersedes all previous task manuals (work instructions) / maintenance procedures on
SIEMENS 3AP1 FG, 3AP1 F1and 3AP1 DT CIRCUIT-BREAKERS with type FA2 MECHANISMS.

SIEMENS 3AP1 FG, 3AP1 F1and 3AP1 CIRCUIT-BREAKERS
Revision history
This edition cancels and replaces edition / revision number 0 of Work Instruction DISINABH3.
Date Rev. Clause Remarks
Nov 2010 0
-
Reviewed By: A K Persadh
Updated Revision information and Included Key words and Bibliography
sections
Changed reference number from DISINABH3 to DMN_34-799.
No change in technical content.
Aug 2005 0 Original issue as DISINABH3
Authorisation
This document has been seen and accepted by:
Name Designation
MN Bailey Corporate Manager Divisional Technology
C Smith TESCOD
Markus Seyffert Maintenance Strategy WG Chairperson
This task manual shall apply throughout Eskom Holdings Limited, its divisions, subsidiaries and entities
wherein Eskom has a controlling interest.
DOCUMENT CLASSIFICATION: CONTROLLED DISCLOSURE
CIRCUIT-BREAKER: SIEMENS, TYPE: 3AP1-FG,
3AP1-F1 AND 3AP1-DT, MECHANISM: FA-2,
RATINGS: 72.5kV-300kV; 4000A; 40-63kA
Unique Identifier: 34-799
Type: DMN
Revision: 0
Page: 3 of 28
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Development team
This Task Manual was initially prepared by: DM Ntombela, Paul Potgieter, Andre Nel. The document was
revised by A Persadh.
Introduction
This Task Manual is compiled to formalize the maintenance task steps for SIEMENS 3AP1 FG, 3AP1
F1and 3AP1 DT CIRCUIT-BREAKERS with type FA2 MECHANISMS. The document includes the latest
updates in information, format, safety precautions from the task analysis and diagrams / photos to make the
document more user-friendly.
Keywords
Maintenance; Materials; Tools; Equipment; PPE; Safety; Circuit-breaker; Mechanism
Bibliography
Not applicable.
1 Scope
This Task Manual standardises the maintenance instructions on SIEMENS 3AP1 FG, 3AP1 F1and 3AP1
DT CIRCUIT-BREAKERS with type FA2 MECHANISMS and is applicable to persons who are authorised
to perform maintenance tasks on these breakers. This document shall apply throughout Eskom Holdings
Limited, its divisions, subsidiaries and entities wherein Eskom has a controlling interest.
2 Normative references
Parties using this manual shall apply the most recent edition of the documents listed below:
2.1 Normative References
Occupational Health and Safety Act and Regulations (OHSAct)
NRS079-1: Mineral Insulating Oils.
EPC_32-846: Rev. 0, Operating Regulations for High Voltage Systems
SCSPBAAY2 Rev. 0, (DPL_34-1005): Environmental management policy.
ESKASABT0 Rev. 0, (DST_32-332): Oil spill clean-up and rehabilitation.
DISASAAT8 Rev. 3, (DST_34-1710): Provision and use of Personal protective equipment.
SCSASAAX4 Rev. 2, (DST_34-1451): Standard for the maintenance of circuit-breakers and oil immersed
isolators.
SCSPVABB1: Rev. 1, (DPC_34-444): Procedure for the application and maintenance of portable earths
DOCUMENT CLASSIFICATION: CONTROLLED DISCLOSURE
CIRCUIT-BREAKER: SIEMENS, TYPE: 3AP1-FG,
3AP1-F1 AND 3AP1-DT, MECHANISM: FA-2,
RATINGS: 72.5kV-300kV; 4000A; 40-63kA
Unique Identifier: 34-799
Type: DMN
Revision: 0
Page: 4 of 28
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to ensure it is in line with the authorised version on the WEB.
SCSPVABF4 Rev. 0, (DPC_34-908): Procedure for Barricading
SCSPVACU1 Rev. 1, (DPC_34-227): Pre-Task Planning and feedback process
Manufacturers manual
2.2 Informative
Not applicable
3 Definitions and abbreviations
3.1 Definitions
All definitions in EPC_32-846 and OHSAct 85 of 1993 are applicable.
3.2 Abbreviations
PTO: Principal Technical Officer;
STO: Senior Technical Officer;
TO: Technical Officer; and
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 that is detailed in this Task Manual.
4.1.1 Plant Managers shall be responsible for:
a) Ensuring that equipment job plans are available and issued for specific maintenance; and
b) Ensuring that the maintenance feedback information / data is captured and recorded into the
system for future maintenance planning.
4.1.2 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 circuit-breakers;
b) Ensuring that this task manual is implemented and adhered to during equipment maintenance;
and
c) Ensuring that circuit-breakers are maintained in accordance with the relevant task manuals.
DOCUMENT CLASSIFICATION: CONTROLLED DISCLOSURE
CIRCUIT-BREAKER: SIEMENS, TYPE: 3AP1-FG,
3AP1-F1 AND 3AP1-DT, MECHANISM: FA-2,
RATINGS: 72.5kV-300kV; 4000A; 40-63kA
Unique Identifier: 34-799
Type: DMN
Revision: 0
Page: 5 of 28
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4.2 First and second line maintenance
a) Insulators cylinders shall be inspected for chips and breakage, a maximum of 20% of chipped or
broken sheds is permitted on an insulator and chips or breaks shall be painted with Glyptol at the
earliest opportunity.
b) Pollution levels on insulators shall be monitored and an anti-pollution medium shall be applied in
accordance with local requirements.
c) There shall be no SF
6
leaks, if any leaks are found these shall only be repaired by authorized
personnel.
d) All gauge glasses shall be clear and legible.
e) All SF
6
pressures shall be correct, there shall be maximum and minimum pressure marks on all
gauges.
f) Mechanism boxes shall be clean and dust free, checks shall be made for any general or obvious
defects.
g) Mechanism box door and cover seals shall be intact.
h) Mechanism heaters shall be operational if a thermostat is fitted, the cut out shall be set at
approximately 25C.
i) The operating label shall be securely mounted and shall be legible from the operating position.
j) All metal work shall be checked for corrosion or rust.
k) The earth straps shall be in a good condition and effectively connected.
l) All feeder trips shall be recorded as fault trips.
m) Where heaters are fitted to SF
6
poles, these heaters shall be operational.
NOTE: All defects found are to be reported to the work management centre with the work order feedback.
4.3 Specialist maintenance
4.3.1 Pre-Planning
4.3.1.1 Materials
a) Klber grease Centroplex 24 DL;
b) Isolflex Topas L32;
c) WD40 or Trost Multifunction fluid;
d) Tectyl 506;
e) Molykote Longterm 2 plus (see figure 1);
f) Castor oil;
DOCUMENT CLASSIFICATION: CONTROLLED DISCLOSURE
CIRCUIT-BREAKER: SIEMENS, TYPE: 3AP1-FG,
3AP1-F1 AND 3AP1-DT, MECHANISM: FA-2,
RATINGS: 72.5kV-300kV; 4000A; 40-63kA
Unique Identifier: 34-799
Type: DMN
Revision: 0
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g) 2 kg sterilized linen cloth;
h) Tin CRC spray;
i) Shell Vaseline 8420 (see figure 1).

Figure 1
j) SF6 gas;
k) Plastic scourer and
l) Electrical cleaner / Shellsol D60, Haku 1025/920, Ethyl alcohol and or Haku 5067.
4.3.1.2 Tools and equipment
NOTE: Never use aerosol lubricants on any part of the mechanism.
a) a set of standard tools;
b) a fibre glass ladder/scaffolding;
c) a speed recorder;
d) a 5 kV insulation tester;
e) a contact resistance tester;
f) a vacuum pump with fittings and hoses;
g) a cleaning tray; and
h) a grease gun.
4.3.1.3 Personal protective equipment
All personal protective equipment shall be in accordance with DST_34-1710.
a) an overall (approved for working with contaminated SF
6
gas / bi-product);
b) a hard hat;
c) safety shoes;
d) goggles;
DOCUMENT CLASSIFICATION: CONTROLLED DISCLOSURE
CIRCUIT-BREAKER: SIEMENS, TYPE: 3AP1-FG,
3AP1-F1 AND 3AP1-DT, MECHANISM: FA-2,
RATINGS: 72.5kV-300kV; 4000A; 40-63kA
Unique Identifier: 34-799
Type: DMN
Revision: 0
Page: 7 of 28
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e) dust mask / respirator;
f) a fall arrestor system; and
g) safety gloves.
4.3.2 Safety and preparation
a) Isolate and earth panel in accordance with EPC_32-846.
b) Erect barricading in accordance with DPC_34-908.
c) Erect scaffolding (where required).
d) Ensure all tools, equipment and materials are placed inside the barricaded area where they will
not hinder or obstruct any worker.
e) Manually close and open the circuit-breaker from the mechanism box to discharge springs.
f) Environmental hazards shall be removed in accordance with DPL_34-1005 and DST_32-332.
g) Isolate the D.C. supply to the panel to prevent accidental closing or tripping of the circuit-breaker.
h) Ensure that when SF
6
gas containers / cylinders are being used whether for refilling or draining
gas from the circuit-breaker poles, that they are protected from the direct sun light, they are not
being overturned and rolled.
i) Ensure that the storage area is well ventilated, that no open flames are allowed in the area and no
eating, drinking or smoking shall take place when handling SF
6
gas.
j) It should be noted that electrical discharges (e.g. switching processes, fault electric arcs) lead to
the formation of gaseous decomposition products and dusty metal compounds. Gaseous
decomposition products of SF
6
exhibit very characteristic warning signs even at low
concentrations. These warning signs are for example pungent or unpleasant odours (like rotten
eggs), or irritation of nose, mouth and eyes. Such irritation occurs within seconds, well in
advance of any danger arising from poisoning.
When handling contaminated SF
6
care must be taken not to breathe in gaseous or dusty
decomposition products. In case this cannot be achieved by technical safety measures, i.e.
ventilation, personal protective equipment must be worn. Personal protective equipment consists
of items of protection for the eyes, body and breathing. More detailed information on handling SF
6

is given in the information leaflet SF
6
plant (Trade Association for Precision Mechanics and
Electrical Engineering) and in the DIN Standard IEC 480 and VDE 0373, Part 2/4.80.
k) If SF6 does not contain any hazardous substances its potential hazards are comparable to those
of new SF6. When SF6 is contaminated with dangerous substances potential hazards exists. The
SF6 decomposition products have an irritating or corrosive effect on eyes, skin and respiratory
system. The presence of small quantities of gaseous decomposition products is accompanied by
clear warning signals in the form of a pungent and unpleasant odour. Irritation occurs within
seconds, well in advance of any danger arising from poisoning.
DOCUMENT CLASSIFICATION: CONTROLLED DISCLOSURE
CIRCUIT-BREAKER: SIEMENS, TYPE: 3AP1-FG,
3AP1-F1 AND 3AP1-DT, MECHANISM: FA-2,
RATINGS: 72.5kV-300kV; 4000A; 40-63kA
Unique Identifier: 34-799
Type: DMN
Revision: 0
Page: 8 of 28
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l) Protective measures: If health hazards associated with the handling of contaminated SF6 cannot
be totally excluded with the aid of technical safety measures, then personal protective clothing
must be worn. Personal safety clothing protects the eyes, the body and includes protective
breathing apparatus. Additional organisational safety measures include the display of operational
instructions and an annual seminar on the potential hazards and the safety precautions to be
adopted when handling SF6 which is contaminated with irritating and corrosive substances.
m) Every waste and or disposable material that has come into contact with SF6 bi-products shall be
disposed in accordance to the Safe Handling of Sulfur Hexafluoride Gas and Its By-Products
(EST_ 32-320).
4.3.3 Maintenance
Risk assessment and critical task analysis shall be done in accordance to DPC_34-227 and approved safe
work procedures before the commencement of work.
4.3.3.1 To open the circuit breaker, follow the next steps:
NOTE: The circuit-breakers must undergo an internal inspection when it has reached 3000 operations, maximum
numbers of fault trips or it has been in service for 12 years. When it reaches 6000 operations or 25 years poles must
be opened and maintained or replace the damaged parts.
Before commencing with any maintenance on the circuit breaker carry out contact resistance and speed
time tests and record for reference (contact resistance of 25, speed times of 31 3ms in opening, 57
6ms in closing and spring rewind time is less than 15 seconds).
a) Ensure that the circuit-breaker is open and the status is indicated on the mechanism indicator and
the mechanism springs are free / discharged.
NOTE: If the pole hasnt been drained ensure that there are four bolts evenly holding the expansion chamber in place
and gas does not leak prior to the removal of the terminal pin or plate. Secure the jumpers safely to ensure that they
are not touching live part of the network.
b) Loosen and remove the jumper connection clamps holding screws, remove the connection
clamps, inspect them for burn marks, oxidation, corrosion and any physical damage.
c) Clean the clamps with electrical cleaner and plastic scourer, dry them up with a lint free cloth and
should they be severely damaged replace them with new ones.
d) Check the circuit-breaker limb/pole insulator for external damages and clean them with electrical
cleaner and wipe them with lint free cloth.
4.3.3.2 Fixed contact
a) To check the fixed contact assembly the poles must be drained off SF
6
gas and follow the next
steps to drain the poles:
Connect the gas filling device / vacuum pump onto the gas cylinder and loosen and
remove the gas filling flange cover / cap.
Connect the gas filling equipment / vacuum pump on the density monitor, and drain the
gas from the circuit-breaker poles into the gas cylinders (see figures 2 & 12).
NOTE: The pressure gauge of the cylinder must be rated at 1100kPa and the filling device safety val ve must be rated
at 900kPa.
Ensure that the pressure gauge on the gas cylinder is rated up to 1100kPa, open the
pressure reducer regulating valve and drain SF6 into the cylinder (see figure 2 (3)).
DOCUMENT CLASSIFICATION: CONTROLLED DISCLOSURE
CIRCUIT-BREAKER: SIEMENS, TYPE: 3AP1-FG,
3AP1-F1 AND 3AP1-DT, MECHANISM: FA-2,
RATINGS: 72.5kV-300kV; 4000A; 40-63kA
Unique Identifier: 34-799
Type: DMN
Revision: 0
Page: 9 of 28
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Figure 2
NOTE: Ensure that appropriate personal protective equipment (Overall, Hard hat, Safety boots, Safety belt, Dust
musk, Goggles and Gloves) are used correctly as the powder that is deposited on the interior parts surface could be
dangerous and ensure not to scratch the insulating cylinder when withdrawing interrupter circuit parts (also refer
from 4.2.2 Safety and preparation paragraph j) and k).
b) Loosen and remove the circuit-breaker expansion chamber / interrupter unit cover screws and
remove the assembly (see figure 3).

Figure 3
c) Dismantle the expansion chamber assembly, inspect the rapture disc for cracks and if the disc is
damaged or ruptured from explosion replace the complete expansion chamber with a new one
(refer to figure 3).
d) Check the upper termination pin / plate for burn marks, oxidation, corrosion any physical damages
and should they be severely damaged, replace them with new ones.
e) Clean the connection terminal pin / plate with electrical cleaner and scourer, dry it up with lint free
cloth (see figure 4).
DOCUMENT CLASSIFICATION: CONTROLLED DISCLOSURE
CIRCUIT-BREAKER: SIEMENS, TYPE: 3AP1-FG,
3AP1-F1 AND 3AP1-DT, MECHANISM: FA-2,
RATINGS: 72.5kV-300kV; 4000A; 40-63kA
Unique Identifier: 34-799
Type: DMN
Revision: 0
Page: 10 of 28
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Figure 4
NOTE: Switching dust shall be vacuumed / cleaned off without being exposed to the air for long as the dust will
absorb moisture and become hard (in about an hour) which will make it difficult to remove.
f) Should there be dust deposits on the fixed contact assembly parts, vacuum the dust off with
vacuum cleaner and remove the fixed contacts from the pole (upper porcelain cylinder / jacket).
g) Measure the distance that the contact arcing tip protrudes from the nozzle guide, the new contact
must measure 9.5mm and it shall be replaced when it measures less than 7mm.
h) Inspect the fixed contact assembly parts (contact carrier, contact lamination and contact arcing
pin) for burn marks, pitting, sputter or any severe physical damages, should the sputter be axially
spread for more than 2mm then the contact support and the moving contact must be replaced.
i) Dismantle the fixed contact assembly, clean the usable contacts with plastic scourer where
necessary and clean them with chlorothene.
j) When the fixed contacts are severely damaged, replace the contact assembly with new ones and
assemble the fixed contacts.
k) Inspect the sealing ring for cracks or damages, if severely damaged replace the seals with new
ones (see figure 5).

Figure 5
4.3.3.3 Arc control device (Turbulator)
NOTE: Replace the arc quenching nozzle after 25 years when necessary
a) Loosen and remove the upper porcelain cylinder / jacket securing screws, remove the cylinder
and inspect it for internal damages.
Head / expansion
chamber seals
Expansion
chamber cover
or rapture disc
DOCUMENT CLASSIFICATION: CONTROLLED DISCLOSURE
CIRCUIT-BREAKER: SIEMENS, TYPE: 3AP1-FG,
3AP1-F1 AND 3AP1-DT, MECHANISM: FA-2,
RATINGS: 72.5kV-300kV; 4000A; 40-63kA
Unique Identifier: 34-799
Type: DMN
Revision: 0
Page: 11 of 28
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b) Remove the arc quenching nozzle from the moving contact assembly, inspect the nozzle for
excessive wear / erosion and replace it with new one when it is severely damaged / eroded (see
figure 6).

Figure 6
NOTE: When the arcing contact pin is severely eroded / damaged, the moving / tube contact must also be replaced.
4.3.3.4 Moving contacts
a) Loosen and remove the moving contact assembly holding screws/bolts and remove the moving
contact.
b) Dismantle the moving contact assembly, check the moving contact assembly parts (heating
cylinder, tube contact, contact rod, contact ring and contact fingers) for burn marks, carbon
deposit and any physical damages (refer to figure 6).
NOTE: Switching dust shall be vacuumed / cleaned off without being exposed to the air for long because the dust
will absorb moisture and become hard which will make it difficult to remove.
c) Should there be any dust deposits on the moving contact assembly parts, vacuum the dust off,
smoothen / clean the contacts with plastic scourer and clean them with chlorothene (refer to figure
6).
d) Should the contact assembly parts be severely damaged, replace any damaged part with a new
one during contact assembling.
e) Remove the moving-contact contact base and the lower terminal from lower porcelain / insulating
cylinder, inspect them for any damage and clean them with scourer and approved solvent.
f) Replace the contact base or the lower terminal with new one if severely damaged during the pole
re-assembling.
g) Loosen and remove the lower insulating porcelain cylinder holding screws and remove the
insulating porcelain cylinder from the crank casing.
h) Inspect the bottom insulating cylinder for cracks, severe chipping or any physical damage, replace
the cylinder with a new one if severely damaged during re-assembling.
i) Check the moving contact insulating rod assembly for any physical damage, should it be severely
damaged replace it with a new one when assembling the contact assembly.
j) Inspect the crank casing parts for any wear, rust and any physical damages, replace the worn or
damaged parts with new ones and when re-assembling ensure that each part is refitted as it was
prior to the maintenance or replacement.
Nozzle
Nozzle Fixed and
Moving contacts
DOCUMENT CLASSIFICATION: CONTROLLED DISCLOSURE
CIRCUIT-BREAKER: SIEMENS, TYPE: 3AP1-FG,
3AP1-F1 AND 3AP1-DT, MECHANISM: FA-2,
RATINGS: 72.5kV-300kV; 4000A; 40-63kA
Unique Identifier: 34-799
Type: DMN
Revision: 0
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4.3.3.5 External mechanism
a) Ensure that the operating mechanism is in off position (by checking the circuit-breaker status on
the internal mechanism structure) and that all the springs in the mechanism box are free /
discharged before commencing with work (see figure 7).

Figure 7
b) Remove the inspection cover from the internal mechanism structure, ensure that the double /
actuating lever joint hole is aligned with position locking hole on the side of every crank casing
(see figure 8).

Figure 8
c) Loosen and remove the SF6 gas pipes from the crank casing, screw crank casing gas adaptor
cover on, inspect the gas pipes for severe oxidation and any deformation or damages (see figure
9).
d) Inspect the coupling / inter-phasing rods to be free from wear, severe oxidation and any
deformation or damages (see figure 9).

Figure 9
Status
indicators
Status
indicators
Status
indicator
Free or
Discharged
springs
DOCUMENT CLASSIFICATION: CONTROLLED DISCLOSURE
CIRCUIT-BREAKER: SIEMENS, TYPE: 3AP1-FG,
3AP1-F1 AND 3AP1-DT, MECHANISM: FA-2,
RATINGS: 72.5kV-300kV; 4000A; 40-63kA
Unique Identifier: 34-799
Type: DMN
Revision: 0
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e) Loosen and remove pivot pin securing screw and washer, remove the coupling / inter-phasing
rods and take not to loose the pivot washers when disassembling the joint (refer to figure 9
above).
f) Insert the pivot pin until it sit into the crank casing locking hole and lock the pin in position by
fitting the locking screw and washer, and tightening it in position (refer to figure 9 above).
NOTE: Switching dust shall be vacuumed / cleaned off without being exposed to the air for long as the dust will
absorb moisture and become hard which will make it difficult to remove.
NOTE: The filter shall not be kept in open air for more than one hour, when one is to be replaced and must be left in
its container / tin until just before the pole evacuation / vacuuming.
g) To check the cranking mechanism, loosen and remove the pole base mounting bolts, remove the
pole base from the structure, remove the filter bag from the crank casing and replace it with a new
one (see figure 10).
NOTE: The disposal of this filter shall be done in accordance to the Safe Handling of Sulfur Hexafluoride Gas and its
by-Products (ESKASAAE1) .

Figure 10
h) Inspect the operating rod for any physical damage, should it be damaged replace it with new one.
i) Vacuum clean the cranking casing mechanism parts and then clean them with chlorothene (refer
to figure 10).
j) Inspect the cranking levers for wear, corrosion and any physical damages, the tightness of the
securing screws and nuts or split pin and washers (refer to figure 10).
4.3.3.6 Density monitor
a) Inspect the gas pipes for obvious physical damages and replace them with new ones when they
are damaged (refer to figure 9 above).
b) Loosen and remove the density monitor cover securing screws and remove cover (see figure 11).
c) Inspect the O ring for cracks and or deformation, replace it when damaged.
Filter
Crank casing
assembly
Crank
casing cover
DOCUMENT CLASSIFICATION: CONTROLLED DISCLOSURE
CIRCUIT-BREAKER: SIEMENS, TYPE: 3AP1-FG,
3AP1-F1 AND 3AP1-DT, MECHANISM: FA-2,
RATINGS: 72.5kV-300kV; 4000A; 40-63kA
Unique Identifier: 34-799
Type: DMN
Revision: 0
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Figure 11
d) Check gas density monitor to be functioning normal and in good conditions, by following the next
steps:
Loosen and remove the test connection cover and connect the W424 testing instrument.
Regulate the pressure by adjusting the pressure reducer to check the low pressure alarm
and lock-out trip pressure: Alarm = 620kPa at 20Cand lock-out = 600kPa at 20C.
Check the cover seal to be in good order and replace with new one when damaged.
Assemble / close the density monitor in reverse order when the testing is completed and
ensure that the O ring is lubricated when assembling.
e) Should the density monitor be damaged replace it with new one (see figure 14 below).
f) Re-fit the density monitor cover into position, insert the securing screws and tighten them.
g) Ensure that the density monitor and the gas pipes are re-fitted or installed correctly when the
assembly is being re-assembled.
4.3.3.7 Re-assembly
NOTE: Ensure that the porcelain insulators are cleaned inside (if the poles were dismantled) and the sealing phase is
cleaned with chlorothene and dried out with lint free cloth and ensure that the ends are covered while waiting to be
re-assembled in order to prevent dust from entering/settling in them.
NOTE: The filter shall not be kept in open air for more than one hour, when one is to be replaced and must be left in
its container / tin until just before the pole evacuation / vacuuming.
a) Assemble the cranking mechanism parts together, re-fit the insulating cylinder, bottom terminal
connection and ensure that all the seals are in position.
b) Assemble the lower terminal connection, contact base and the moving contact assembly together,
re-fit the upper porcelain cylinder, ensure that the seals are in position, insert the assembly
holding screws and tighten them.
c) Re-fit the fixed contact assembly into position, insert the securing screws / bolts and tighten them
d) Re-fit the explosion chamber assembly onto position, insert the holding screws and tighten them
and ensure that the rupturing plate is in good condition and secured.
e) Fit all poles onto the external mechanism structure in the following manner:
First fit the middle phase pole onto the structure, position both the inter-phasing rods and
align the pole to the inter-phasing rods.
DOCUMENT CLASSIFICATION: CONTROLLED DISCLOSURE
CIRCUIT-BREAKER: SIEMENS, TYPE: 3AP1-FG,
3AP1-F1 AND 3AP1-DT, MECHANISM: FA-2,
RATINGS: 72.5kV-300kV; 4000A; 40-63kA
Unique Identifier: 34-799
Type: DMN
Revision: 0
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Fit the pivot pin until it locks the double lever movement in relation to the casing (until it
reaches the end of the hole on the side of the crank casing) and insert the pole securing
bolts and tighten them (see figure 12).

Figure 12
Fit the other two phases on the structure, fit and align them in relation to the inter-phasing
rods, insert the pivot pins through to the end of the locking hole on the crank casing, fit the
securing bolts and tighten them.
Pull / retract the pivot pins until the groove on the pin appears (level with double lever
outer holes), fit the pin securing washers in the grooves, insert the securing screws and
tighten the screws to hold the pin in position (see figure 13).

Figure 13
f) Remove the gas pipes adaptor, poles gas inlet covers and O rings from the pipes and gas inlets,
for a new pole that has been factory filled with gas, depress the valve on the casing to check the
gas pressure in the poles and if no hissing noise is head gas has leaked from the pole and the
pole could be damaged.
g) Should any the new poles be damaged or have a gas leak, the pole shall be checked before
assembling, then lubricate the O rings with Vaseline and fit the O ring into the coupler nut, fit
the SF6 gas pipes onto the crank casings inlets and tighten the nuts (see figure 15).
NOTE: The filter shall not be kept in open air for more than one hour, when one is to be replaced and must be left in
its container / tin until just before the pole evacuation / vacuuming.
NOTE: The poles must always be evacuated / vacuumed whenever they have been opened.
h) Loosen and remove the crank casing cover, inspect the O sealing rings for any damages, apply
Vaseline onto the seals, insert the filters into the casing, place the cover into position and tighten
the securing screws.
i) To fill the poles with gas follow the next steps:
Pivot pin must be
pushed until it
locks onto the
crank casing.
DOCUMENT CLASSIFICATION: CONTROLLED DISCLOSURE
CIRCUIT-BREAKER: SIEMENS, TYPE: 3AP1-FG,
3AP1-F1 AND 3AP1-DT, MECHANISM: FA-2,
RATINGS: 72.5kV-300kV; 4000A; 40-63kA
Unique Identifier: 34-799
Type: DMN
Revision: 0
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When using the filling device type W423, loosen and remove filling flange cover and
connect the filling device hose (as per manufacturer manual) onto the filling flange (see
figure 14).

Figure 14
With the device connected to the cylinder slowly open the regulator valve at the pressure
reducer with vent valve closed to avoid ice formation on the fitting and the poles shall be
filled to the pressure above 7bar (700kPa).
When using vacuum pump / servicing unit W424 the circuit-breaker poles shall be
vacuumed / evacuated to the pressure of 2kPa before filling them with SF6 gas (refer to
figure 14).
Then switch the unit to filling and fill the poles with SF6 gas to the pressure above 7bar
(700kPa) and when filling is complete remove the hoses and refit the union nut and
tighten it by hand.
j) Ensure that the gas pipes connected to crank casing and to the density monitor are tightly
connected and the gas pressure is correct, should the density monitor be faulty, replace it with
new one (see figure 15).

Figure 15
k) Use the gas tester or soapy water to detect the gas leaks (see the gas tester on 16 below).

Figure 16
DOCUMENT CLASSIFICATION: CONTROLLED DISCLOSURE
CIRCUIT-BREAKER: SIEMENS, TYPE: 3AP1-FG,
3AP1-F1 AND 3AP1-DT, MECHANISM: FA-2,
RATINGS: 72.5kV-300kV; 4000A; 40-63kA
Unique Identifier: 34-799
Type: DMN
Revision: 0
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l) To test the density monitor follow the steps under section 4.3 Testing, below.
4.3.3.8 Mechanism
a) Ensure that the operating mechanism is in off position (by checking the circuit-breaker status on
the internal mechanism structure) and ensure that all springs in the mechanism box are free /
discharged before commencing with work (refer to figure 7 under section 4.2.3.9 External
Mechanism).
b) Open the mechanism door and ensure that all springs are discharged before commencing with
any work on the mechanism (see figure 17).

Figure 17
c) Clean the mechanism off dust and excessive grime deposits with clean linen cloth, ensuring that
no fluff or bits of thread from the cloth are left behind to impair the operations of the mechanism.
d) Check all shafts, gear, chains, sprockets, springs, split pins, pivot pins, latches, cams and links for
rust, wear and for any physical damages (see figure 18).

Figure 18
e) Should any of the pivot pins, latches, cams or links be rusted, worn or show signs of physical
deformation replace them with new ones (see figure 19).

Figure 19
DOCUMENT CLASSIFICATION: CONTROLLED DISCLOSURE
CIRCUIT-BREAKER: SIEMENS, TYPE: 3AP1-FG,
3AP1-F1 AND 3AP1-DT, MECHANISM: FA-2,
RATINGS: 72.5kV-300kV; 4000A; 40-63kA
Unique Identifier: 34-799
Type: DMN
Revision: 0
Page: 18 of 28
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f) Check the auxiliary contacts to be in order, if not replace as follows (see figure 20).

Figure 20
To replace the auxiliary contacts, label, disconnect and remove all connected wires.
Loosen and remove the auxiliary contact assembly holding screws and remove the
auxiliary contacts.
Re-fit the auxiliary contact assembly and tighten the holding screws.
Reconnect the wires according to the labelling / numbering and tighten the connection
screws.
g) Check the micro-switches to be functioning and free from dirt and cracks, if the micro-switches are
damaged, label, disconnect and remove the connected wires, loosen and remove the securing
screws and remove the micro-switches.
h) Re-fit the micro switches, insert the securing screws, tighten them and reconnect the wires again.
i) Check the spring rewind motor assembly to be in functioning order, if not follow the next steps:
Disconnect and remove the supply wires (see figure 21).

Figure 21
Loosen and remove the screws holding the motor onto the mechanism and remove the
motor assembly.
j) The damaged motor could be replaced with a complete new one where one is available.
k) Dismantle the spring rewind motor assembly as follow:
Remove the motor brushes, check the brushes to be in order, if not replace them with
new ones.
DOCUMENT CLASSIFICATION: CONTROLLED DISCLOSURE
CIRCUIT-BREAKER: SIEMENS, TYPE: 3AP1-FG,
3AP1-F1 AND 3AP1-DT, MECHANISM: FA-2,
RATINGS: 72.5kV-300kV; 4000A; 40-63kA
Unique Identifier: 34-799
Type: DMN
Revision: 0
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Where the motor bushes or bearing must be replaced, loosen and remove the screws
holding the motor assembly together and disassemble the motor.
l) Check the commutator segments for burn marks, carbon deposit and excessive wear.
m) Should the commutator be damaged, loosen and remove the bolts holding the motor together and
replace the commutator.
n) Assemble the motor, re-fit it onto the mechanism, insert the holding screws and tighten them.
NOTE: When a complete motor assembly is available, the old one can be exchanged or replaced by new one.
o) Check the condition of the tripping and closing coils if damaged replace them with new ones (see
figure 22).

Figure 22
p) Check the mechanism operation counter to be functional and replace it if damaged (see figure
23).

Figure 23
q) Inspect the mechanism box door seal and locking mechanism / handle to be in order, replace
them with new whenever they are severely damaged (see figure 24).
r) Check the mechanism box anti-condensation heaters to be functional and replace them with new
ones when damaged (see figure 24).
s) Clean off the excess grease from operating mechanism assembly with a lint free cloth.
t) Ensure that all un-used cable holes on the mechanism box are plugged / closed.
Closing tripping and
backup tripping coils
DOCUMENT CLASSIFICATION: CONTROLLED DISCLOSURE
CIRCUIT-BREAKER: SIEMENS, TYPE: 3AP1-FG,
3AP1-F1 AND 3AP1-DT, MECHANISM: FA-2,
RATINGS: 72.5kV-300kV; 4000A; 40-63kA
Unique Identifier: 34-799
Type: DMN
Revision: 0
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Figure 24
u) Check and ensure that the ventilators are not blocked if blocked clean them out (see figure 25)

Figure 25
4.3.3.9 Adjustments
Not applicable.
4.3.4 Modifications
Not applicable.
4.4 Testing
a) Test the contact resistance across the main and transfer contacts: maximum 25 per phase.
b) Test the minimum release voltage of main and back-up trip coils: it should be 85 % of nominal
voltage.
c) Measure the trip and close coil currents.
d) Check the closing and opening times with a speed recorder:
opening time 31 3 ms;
closing time 57 6ms.
Note the spring rewind time of the motor: it should be < 15s.
e) Record the resistance values of the coils for future reference.
DOCUMENT CLASSIFICATION: CONTROLLED DISCLOSURE
CIRCUIT-BREAKER: SIEMENS, TYPE: 3AP1-FG,
3AP1-F1 AND 3AP1-DT, MECHANISM: FA-2,
RATINGS: 72.5kV-300kV; 4000A; 40-63kA
Unique Identifier: 34-799
Type: DMN
Revision: 0
Page: 21 of 28
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Note the maximum allowable time discrepancies between phases:
close a maximum of 6ms;
open a maximum of 3ms.
f) Carry out an insulation test if leakage to earth is suspected due to damaged bushings,
contaminated oil or if excessive moisture is found inside the circuit-breaker pole.
g) Test the functions of the density monitor to be in order, follow the next steps to check:
Remove the test connection flange cover and observe the reaction of the monitors
contacts.
Connect the filling unit hose onto the filling connection flange.
Regulate the pressure by adjusting the pressure reducer to check the low pressure alarm
and lock-out trip pressure: Alarm = 620kPa at 20Cand lock-out = 600kPa at 20C.
5 Related/Supporting Documents
5.1 Related Documents
a) Critical task analysis:
1. Work in Live Chambers and Prohibited areas;
2. High Voltage Operating; and
3. Work with/on Extension/Single Ladders.
b) Training module;
c) Manufacturers manual.
5.2 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 co-ordinator and a copy thereof shall be sent to or kept at the Technical Specialist Group (TSG).
6 Spares
Refer to Error! Reference source not found.: Error! Reference source not found.
DOCUMENT CLASSIFICATION: CONTROLLED DISCLOSURE
CIRCUIT-BREAKER: SIEMENS, TYPE: 3AP1-FG,
3AP1-F1 AND 3AP1-DT, MECHANISM: FA-2,
RATINGS: 72.5kV-300kV; 4000A; 40-63kA
Unique Identifier: 34-799
Type: DMN
Revision: 0
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Annex A - Circuit-breaker / Recloser report
SUBSTATION PANEL / FEEDER POLE NUMBER


Circuit-breaker / Recloser
MAKE TYPE SERIAL NUMBER
R Ph:
kV AMPS kA W Ph:
B Ph:

Mechanism
TYPE DRIVE SERIAL NUMBER
R Ph:
HEATER COUNTER W Ph:
Before: After: B Ph:
SUPPLY VOLTAGE: (tick which is applicable) 110 V D.C. 220V D.C. 220V A.C.

Tests
Contact resistance (micro-ohm) Contact penetration (mm)
R Phase W Phase B Phase R Phase W Phase B Phase
TEST 1
TEST 2
TEST 3

COILS
Minimum trip release voltage Minimum close release voltage:
Main Back-up Coil amperage
R Ph: R Ph: Main trip: Back-up: Close:
W Ph: W Ph: Coil resistance
B Ph: B Ph: Main trip: Back-up: Close:
DOCUMENT CLASSIFICATION: CONTROLLED DISCLOSURE
CIRCUIT-BREAKER: SIEMENS, TYPE: 3AP1-FG,
3AP1-F1 AND 3AP1-DT, MECHANISM: FA-2,
RATINGS: 72.5kV-300kV; 4000A; 40-63kA
Unique Identifier: 34-799
Type: DMN
Revision: 0
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Annex A
(Continued)
Speed recording test
Phase Close Trip Trip/close Close/trip
Red A
Red B
White A
White B
Blue A
Blue B
Motor rewind time to recharge spring:
Time discrepancies between phases Trip: Close:

Insulation test SF
6
gas alarm test
R Phase W Phase B Phase Nominal at 21
o
C
S to E Alarms
L to E Lock-out at
S to L


DOCUMENT CLASSIFICATION: CONTROLLED DISCLOSURE
CIRCUIT-BREAKER: SIEMENS, TYPE: 3AP1-FG,
3AP1-F1 AND 3AP1-DT, MECHANISM: FA-2,
RATINGS: 72.5kV-300kV; 4000A; 40-63kA
Unique Identifier: 34-799
Type: DMN
Revision: 0
Page: 24 of 28
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Annex A
(concluded)
Recloser settings
first time second time Operations Number
Overcurrent To lock-out
Earth fault Fast
operations

Sensitive E/F Slow
operations


Checklist
Good Replaced Good Replaced Good Replaced
Fixed contacts Oil Coils
Arcing ring Gauge glasses Motors
Moving contacts Seals Pumps
Transfer contacts Valves Contactor
Arc control device Door seals Counters
Inspect Lubricate Free Inspect Lubricate No leaks
Close latch Drives
Trip latch Damper
Needle bearings Springs
Interlocks Shafts

RECOMMENDATIONS:




WORK DONE BY: . SIGNATURE: .

ACCEPTED BY: DATE: ..
DOCUMENT CLASSIFICATION: CONTROLLED DISCLOSURE
CIRCUIT-BREAKER: SIEMENS, TYPE: 3AP1-FG,
3AP1-F1 AND 3AP1-DT, MECHANISM: FA-2,
RATINGS: 72.5kV-300kV; 4000A; 40-63kA
Unique Identifier: 34-799
Type: DMN
Revision: 0
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Annex B Impact Assessment
(Normative)
Impact assessment form to be completed for all documents.
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, optimised costs.
Comment: Statutory requirements to be met with 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: Statutory requirements to be met with.
2.3 Impact on stock holding and depletion of existing stock prior to switch over.
Comment: N/A - No new equipment or item needed 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 interchangeability of the product or item been verified - i.e. when it fails is a straight
swop possible with a competitor's product?
Comment: N/A It is a maintenance document. 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: Refer to equipment maintenance documents when implementing this document.
2.7 Provide details of any comments made by the Regions regarding the implementation of this
document.
Comment: (N/A)
DOCUMENT CLASSIFICATION: CONTROLLED DISCLOSURE
CIRCUIT-BREAKER: SIEMENS, TYPE: 3AP1-FG,
3AP1-F1 AND 3AP1-DT, MECHANISM: FA-2,
RATINGS: 72.5kV-300kV; 4000A; 40-63kA
Unique Identifier: 34-799
Type: DMN
Revision: 0
Page: 26 of 28
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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 Buyers 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: N/A
4.4 If the implementation of this document requires assessment by CAP, provide details under 5.
N/A
4.5 Which Power Office packages have been created, modified or removed?
Comment: N/A
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: The document doesnt specify but stipulates the maintenance procedures on the existing
equipment.
5.3 Are ALL suppliers (currently accepted per LAP), aware of the nature of changes contained in
this document?
Comment: N/A Specifications are supplied to suppliers.
DOCUMENT CLASSIFICATION: CONTROLLED DISCLOSURE
CIRCUIT-BREAKER: SIEMENS, TYPE: 3AP1-FG,
3AP1-F1 AND 3AP1-DT, MECHANISM: FA-2,
RATINGS: 72.5kV-300kV; 4000A; 40-63kA
Unique Identifier: 34-799
Type: DMN
Revision: 0
Page: 27 of 28
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Annex B
(continued)
5.4 Is implementation of the provisions of this document required during the current supplier
qualification period?
Comment: Yes This is the revision of a document that is presently being implemented and requires no
change to the suppliers qualification period.
5.5 If Yes to 5.4, what date has been set for all currently accepted suppliers to comply fully?
Comment: N/A. See 5.4 above.
5.6 If Yes to 5.4, have all currently accepted suppliers been sent a prior formal notification
informing them of Eskoms expectations, including the implementation date deadline?
Comment: N/A See 5.5 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 Is training required?
Comment: Yes
6.2 State the level of training required to implement this document. (E.g. awareness training,
practical / on job, module, etc.)
Comment: Practical / On job and training module.
6.3 State designations of personnel that will require training.
Comment: TSO, PTO & STO.
6.4 Is the training material available? Identify person responsible for the development of training
material.
Comment: No. The Training module is still under development (Alec Aylward)
6.5 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.
DOCUMENT CLASSIFICATION: CONTROLLED DISCLOSURE
CIRCUIT-BREAKER: SIEMENS, TYPE: 3AP1-FG,
3AP1-F1 AND 3AP1-DT, MECHANISM: FA-2,
RATINGS: 72.5kV-300kV; 4000A; 40-63kA
Unique Identifier: 34-799
Type: DMN
Revision: 0
Page: 28 of 28
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Annex B
(continued)
6.6 Was Technical Training Section consulted w.r.t. module development process?
Comment: Yes.
6.7 State communications channels to be used to inform target audience.
Comment: Regional TFCC meetings.
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
7.3 What will be the costs of these special tools, equipment, software? N/A
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 training will be incurred by the regions. This will depend on the
arrangements made for training i.e. whether training is held regionally or nationally.
Impact assessment completed by:
Name: A. Persadh
Designation: Senior Advisor