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Substation name
Customer
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Location
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Table of contents
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1. General information
Audit
Customer
Country South Africa
Location
Substation name
Asset type Siemens 8BD 11kV & 3.3kV
Type Siemens 8BD Panels 3AC / 3TL5
Serial number B4E213765
Date 2014/01/13
Remarks Audit for assessing life-time status
Auditor
Name Niels Inderbiethen
Department AFR RC-ZA IC-SG SE MCS
Telephone +27 (10) 222-7315
Fax
E-mail niels.inderbiethen@siemens.com
Customer data
Contact person (technical)
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Technical Information
Manufacturer Siemens
Type designation of switchgear Siemens RSA Type: 8BD 11kV 25kA
& 3.3kV with 3AC Circuit breaker &
3TL5 Contactor Trucks
Standard IEC 60298 / VDE 0670-6 (metall
closed)
Year of manufacture of switchgear 1976
Substation arrangement Double busbar
Installation Indoor
Number of bays 5
Number of spare bays A few may become available once
plant redundancy is established
Serial numbers TBA
Air insulated metall closed switchgear Yes
Gasinsulated metall closed switchgear No
Remark none
General remarks by auditor There is a serious water problem in
the cable basement
General remarks by customer problems with corrosion and blow ups
being experienced
Rated voltage 12 kV
Rated lightning impulse withstand voltage 95 kV
Control voltage (DC/AC) DC
Control voltage 110 V
Rated short circuit breaking current 25 kA
Maximum busbar current 2000 A
Rated current supply 2000 A
Rated current feeder 1600 A
Historical Information
Years of operation since first commissioning 36-40 years
Are maintenance reports available? No
Have circuit breakers been modified? Yes
When? Various occasions
Remarks some are from other switchgear
panels
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Switchgear 80 Bushings
accessories
60
Protection and 20
Condition of building
secondary system 0
Natural
Grounding
Ageing
Maintenance requirements
Natural Ageing ████ Very critical attributes were found. Immediate action required.
Safety ████ Very critical attributes were found. Immediate action required.
Condition of building ████ Critical attributes were found. Repair or replace as soon as possible.
Switchgear accessories ████ Very critical attributes were found. Immediate action required.
Circuit breaker ████ Very critical attributes were found. Immediate action required.
Load-break switch ████ Very critical attributes were found. Immediate action required.
Grounding ████ No unfavorable attributes were found. No action is required.
Post insulators ████ Very critical attributes were found. Immediate action required.
Bushings ████ Very critical attributes were found. Immediate action required.
Busbars ████ Very critical attributes were found. Immediate action required.
Current transformer ████ Harmful attributes were found. Repair during next planned maintenance (monitoring).
Voltage transformer ████ Very critical attributes were found. Immediate action required.
Metering ████ Harmful attributes were found. Repair during next planned maintenance (monitoring).
Measurement ████ Harmful attributes were found. Repair during next planned maintenance (monitoring).
Prot & sec system ████ Harmful attributes were found. Repair during next planned maintenance (monitoring).
Low voltage switchgear ████ Very critical attributes were found. Immediate action required.
Battery system ████ Harmful attributes were found. Repair during next planned maintenance (monitoring).
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3.3kV Panel photo’s (continued)
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The cable compartments also look affected by corrosion due to the moisture, however these areas can
also be treated re-painted or coated with resin to ensure a long life further forward. The cables however
have been immersed in the water below the cable trench for some time now and ideally these should all
be tested to ensure that the insulation has not been compromised.
However if civil work is done to stop the water problem this will no longer have any affect on the cable life
expectancy and they will remain dry.
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4. Safety
Staff protection
Country-specific standards
Country-specific standards considered? Yes
Which kind of? SANS
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Environment
Altitude of site 1000 m up to 2000 m
Ambient temperature range - 5 °C up to + 40 °C
Current temperature on substation site 28
Quality of the ambient atmosphere Very humid
Installation in seismic zone No
Remark Coal dust present inside panel
contributing to problems
Building
outside
Ventilation, air exhaust louver, pick safety Bad, big impact deficiencies
Remark no heaters & positive pressure
Pressure relief building Bad, big impact deficiencies
Remark high moisture content - cannot be
rectified without civil works & damp /
waterproofing
inside
Aisle widths sufficient / escape route available good, no defects
Remark none
Floor, floor plates Bad, big impact deficiencies
Remark Allows the water vapour to penetrate
substation from basement
Cable basement, cable vault Bad, big impact deficiencies
Remark flooded permanently
Electro-installation, lighting Bad, big impact deficiencies
Remark everything in this station is losing life
expectancy due to corrosion
Pollution, Humidity Bad, big impact deficiencies
Remark leaks & water from roof area, wall
areas and basement
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Switchgear accessories
Isolating protective plates VDE 0682-552 Bad, big impact deficiencies
Remark some work & repairs will be required
Guide strips for protective plates Bad, big impact deficiencies
Remark corrosion
Grounding accessories VDE 683T100 Bad, big impact deficiencies
Remark Earth copper theft problem -
suggestion to replace earth copper
with aluminium / steel
Voltage tester VDE 682T411 Bad, big impact deficiencies
Remark was not functioning (equipment
assessment to be done or
replacement considered
Fuse tongs VDE 681T3 Bad, big impact deficiencies
Remark some equipment for panel operations
maintenance is missing or lost
SF6-Maintenance unit available No
Switching devices
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Earthable fixpoints
Are earthable points installed? No
Components
Post insulators
Are post insulators installed? Yes
Type Cast resin
Diagnosis Bad, big impact deficiencies
Condition Dirty
Remark becoming saturated with moisture
Bushings
Are bushings installed? Yes
Type Cast resin
Diagnosis Bad, big impact deficiencies
Condition Damaged
Remark damaged cover flaps & dirt / carbon
build up is dangerously high
Busbars
Are busbars installed? Yes
Insulation Air insulated
Material Copper
Cross section 2 by 10
Diagnosis Bad, big impact deficiencies
Remark as per pics the copper inside the panel
has all turned seriously blue from
oxidation, moisture, harmful
atmosphere & the resulting corrosion
Current rails
Are current rails installed? No
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Voltage transformer
Are voltage transformers installed? Yes
Design Conventional
Type 8BD - VT Rueksak
Year of manufacture same as panel
Manufacturer Siemens
Quantity 1 on the 11kV Board & 1 on the 3.3kV
board
Serial numbers not visible during operation
Primary voltage (Example: 110 000/√³ V) 11000
Secondary voltage of the measurement winding (Example: 110/√³ V) 110
Earth fault winding Yes
Class standard 11kV VT
Voltage factor (Example: 1.9 * Un, 4 h) standard
Diagnosis Bad, big impact deficiencies
Condition of voltage transformer Very dirty
Remark a complete opening of VT housing is
recommended and clean and full
service and test
Surge Arresters
Are surge arresters installed? No
Secondary Systems
Metering
Is a counting facility available? Yes
Manufacturer various as per each panel LT relays
mounted in relay compartment
Type also various
Diagnosis Medium, insignificant deficiencies
Remark we assume or suggest that all
protection relays are all tested at least
once each year for full functionality
and records of this are/ must be kept
in the substation
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Measurement
Is a measuring facility available? Yes
Manufacturer Various
Type KWH Relays
Diagnosis Medium, insignificant deficiencies
Remark we assume or suggest that all
protection relays are all tested at least
once each year for full functionality
and records of this are/ must be kept
in the substation
Protection
Are protection devices installed? Yes
Protection electromechanical
Distance Protection
Distance Protection Yes
Manufacturer GE
Type Electromechanical
Diagnosis Medium, insignificant deficiencies
Remark we assume or suggest that all
protection relays are all tested at least
once each year for full functionality
and records of this are/ must be kept
in the substation
Differential Protection
Differential Protection Yes
Manufacturer GE
Type Electromechanical
Diagnosis Medium, insignificant deficiencies
Remark we assume or suggest that all
protection relays are all tested at least
once each year for full functionality
and records of this are/ must be kept
in the substation
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Busbar protection
Busbar protection No
Battery system
Does DC auxiliary supply equipment exist? Yes
Manufacturer various
Type various
Year of manufacture various
Diagnosis Medium, insignificant deficiencies
Remark we assume or suggest that all
protection relays are all tested at least
once each year for full functionality
and records of this are/ must be kept
in the substation
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Other
Other none
Documentation
Documentation
Documentation Not available/not installed
Remark we could only visibly see the single
lines, all sundry documentation for
every control circuit present in the sub
should be openly available and
accessibly labelled
Files
Attach file 1 All pics Ziped1.zip
Attach file 2 All pics Ziped1_2.zip
Attach file 3 All Pics for 11kV Board 1 of 2.zip
Attach file 4 All Pics for 11kV Board 2 of 2.zip
Audit Configuration
The first level of the audit is complete. How do you want to proceed? -The customer requests FUTURE
consulting or thorough investigations
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6. Environmental sustainability
Conclusion
Important status parameters of the tested system indicate high risk of environmental hazard. Please observe the
maintenance recommendations. The general status of the substation environmental condition is presently poor
due to the water and damp leaks into the substation. Although one must mention that the general safety applied
in the station is good.
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7. Maintenance recommendations
Safety
- The located weakpoints regarding personnel protection insulation have to be removed immediately
Natural Ageing
- The actual ambient conditions may require additional maintenance works
Condition of building
outside
inside
Switchgear accessories
- Exchanging equipment - (start planing for older equipment exchanges)
- Exchanging equipment - (Check enough critical spares are still on hand to have sufficient time to implement)
- Exchanging equipment - (after anual testing, if found faulty, exchange with new as necessary or advised)
- Exchanging equipment - (circuit breakers can easily be exchanged (oil fire hazzard) rather for new vacuum)
- Exchanging equipment – (contactors can easily be exchanged / retrofitted with new ones at minmal outlay)
Load-break switch
Post insulators
- Maintenance of insulators.
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Bushings
- Maintenance of insulators.
Busbars
- Maintenance of insulators.
Current transformer
Voltage transformer
- Maintenance respectively repair of the instrument transformer
1
Please note:
This audit report summarizes only the existing condition of the customer’s electrical equipment and system at the time when the audit was performed.
Please note that any subsequent changes of the equipment, system or equipment’s operation may cause inconsistency between the report’s
summary and the subsequently changed conditions. Siemens cannot be held liable for such inconsistency.
Charts, diagrams and graphics in this report are merely illustrations to summarize and to provide an overview of the condition of the customer’s
electrical equipment and system at the time the audit was performed. No conclusions should be made and no further measures should be taken
based exclusively on the graphic presentations included in this report.
Siemens shall not be liable if the information included in this report is not handled or otherwise used with the necessary expert knowledge and
thereby damage of any kind is caused.
Siemens shall not be held liable for technical developments which supersede or invalidate the information in the report, if these could not have been
reasonably known or identified prior to the time when the audit was performed.
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