The 3.3kV and 11kV switchgear panels at the substation are experiencing serious issues due to long-term water exposure from the cable basement. Rust and deterioration are widespread due to the high moisture content. While the panels could be retrofitted with new circuit breakers and contactors, the root cause of water ingress must be addressed through major civil works to fully repair leaks from walls and the basement. Otherwise, any refurbishment would have limited lifespan. Most components are in poor condition due to corrosion and have critical maintenance requirements. The safety hazards posed by the deterioration are also of serious concern.

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Technical Report
SAFE™ Audit of 3.3 & 11kV Switchoards
Substation name
Customer
Location
2014/01/13

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Table of contents
1. General information......................................................................................................3
2. Chart of Medium voltage condition.............................................................................5
3. Summary .......................................................................................................................6
4. Safety...........................................................................................................................13
5. Visual inspection when asset in operation...............................................................14
6. Environmental sustainability .....................................................................................25
7. Maintenance recommendations ................................................................................26

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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)
Telephone number of the contact person TBA
Fax number of contact person TBA
E-mail of contact person TBA
Postal Code TBA
Town
Street, No.

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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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2. Chart of Medium voltage condition
(Weighted average of evaluated attributes. 0: very good --> 100: bad)
0
20
40
60
80
100
Battery system
Busbars
Bushings
Circuit breaker
Condition of building
Current transformer
Grounding
Load-break switch
Low voltage
switchgear
Measurement
Metering
Natural
Ageing
Post insulators
Protection and
secondary system
Safety
Switchgear
accessories
Voltage transformer
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. Summary
The 3.3kV Panel is being affected by the water
moisture from the cable trench, rust &
deterioration is evident on all parts and
components. The copper has turned blue from
oxidation although the equipment can be
exchanged by retrofit and all parts can be
restored by our artisans. It is however essential
for further life expectancy not to be affected
negatively from such a point forward, that all
leaks from walls, basement and roof areas are
fully repaired by major civil work, if required.
A larger expenditure on the civil side will ensure
that any refurbishment undertaken would last in
simillar time period to a completely new panel.
The circuit breakers and contactors can be
retrofitted with new equipment as this is the heart
of the switching & equipment.
3.3kV Panel photo’s

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Panel 01 Panel 02 Panel 03 Panel 04 Panel 05
Doors of the LT compartment are relatively
easy to replace and new cut-outs could be
introduced for the protection that is
required, even if the relays are considered
to be changed for any different application.
Another advantage of leaving the old panel
in place and refurbishing in situ, is that all
cables can remain connected, or re-
terminated if suspect, being left
undisturbed without placing stress on them
as would occur if panels are completely
removed and replaced.
The old front covers would naturally be
replaced if the circuit breaker and
contactor trucks are retro-fitted with new
equipment giving the panel front a
completely new appearance with the
retrofit new front covers that would be
completely re-sprayed (properly powder-
coated).
We noted that the LT compartment wiring
and terminals are still in a good condition
and this could even remain as it is without
any new re-wiring costs, One would
possibly only need to replace a terminal or
re-do a connection here or there, but the
present condition makes for easy new
equipment wiring integration. There were a
few melted trunking pieces noted however
anything of this nature can be replaced
quickly and easily at no major cost impact
3.3kV Panel photo’s (continued)

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CT housings, although they will become more
porous with age and may attract moisture, fitting
heaters in these panels in each tier can
overcome these problems and really extend the
life of this equipment. It is not to say that they
are guaranteed to last forever, but from our past
experience with retro-fitting we must mention
that thusfar no major failures have been
experiend simply due to age, as all failures are
usually mostly triggered by a specific cause.
Contacts within the busbar housing connecting
the c/b arms can all be cleaned checked and
replaced if necessary.
Circuit Breakers & Contactor Photo’s
The circuit breakers and contactors are more problematic as these pose the greatest of all issues for
further use. Due to oil fire hazzards, we would recommend to go for vacuum exchange breakers and
contactors as this would be most cost effective. SF6 is slightly more expensive and can also be a lot
more specialised & problematic to maintain. Vacuum you can basically install & not worry about.
3.3kV Panel photo’s (continued) – Busbar Chamber

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Circuit Breakers & Contactors
continued
If contactors are retro-fitted the
advantage of fuse protection ,
esscpecially on motors is not lost. Fuses
are relativelt easy to obtain and still
provide the best and fastest protection.
3.3kV Panel photo’s (continued)

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In past experience we have seen many times that
electromechanical relays can outperform much of
the digital technology available today. Digital relays
are very temperature sensative and generally there
are many reports of relays failing or losing e-prom
memory due to the temparatures in electrical panels
sometimes exceeding 47 degrees in summer during
heavy feeder loading when temperatures rise even
within the LT compartment. Due to the fact that there
is no forced cooling in the sub and that installing
such system is very expensive, we must side with
advising to stick with the present protection systems
installed. If these are regularly tested and calibrated
they will still work for a very long time without giving
much trouble, as contacts, bi-metals and coils can
be easily replaced.
11 kV Switchboard Panel photo’s

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11kV Panel 01 11kV Panel 02 11kV Panel 03 11kV Panel 04
All parts on the equipment
now visibly damaged would
be completely new with a
retro-fitted solution. We would
also advise to exchange the
spouts as these are part of
the safety and protection,
11kV Panel General Overview photo‘s
11kV Panels 01 to 04 visual front view

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11kV Panel Busbar Chamber internal photo‘s
The busbar chambers are in need of immediate attention, however it must be
stated that repairing the existing copper, cleaning it so that the surface is again
shiny and then rather ray-chem sleeving this or using a type of resin paint on all
non-contact surface areas, would again renew and protect the copper for a very
long time. Insulators can all be exchanged cheaply and all the contact spouts can
also be replaced with new ones. Re-allignment can be checked if correct and set
if not. Fire protection or proofing can also be done in any open areas toward the
basement by closing any openings. Heaters can also be fitted in busbar chamber
to retain dry conditions. For any chambers with prior damage they may also either
be painted with glyptol, or a new piece of thinly cut haysite can be aplied to
damaged metal areas to prevent future flashovers completely in these areas.
11kV Panel Cable Compartment internal photo‘s
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
Personnel protection insulation DIN VDE 0106 (IEC 60990)
Personnel protection insulation DIN VDE 0106 (IEC 60990) Bad, big impact deficiencies
Remark the moisture and carbon corrosion are
posing serious dangers to safe
ongoing switching
Operational safety DIN VDE 0101 (IEC 61936)
Load-break switch instead of disconnector Bad, big impact deficiencies
Remark corrosion
Switchgear interlocking unit Bad, big impact deficiencies
Remark corrosion
Operation from a safe distance Bad, big impact deficiencies
Remark operation has to be performed
manually
Installation of suitable electro-sensitive protective equipment Bad, big impact deficiencies
Remark water dust & moisture creating semi-
conductive earth paths
Country-specific standards
Country-specific standards considered? Yes
Which kind of? SANS
11kV Panel Circuit Breaker Chamber internal photo‘s

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5. Visual inspection when asset in operation
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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First type of circuit breaker
Are circuit breakers installed? Yes
Principle of interruption Minimum oil
Number of circuit breakers 5 3AC type Circuit breakers and 3 type
3TL5 Vacuum contactors mixed in
8BD 11/3.3 kV Panel
Type designation of circuit breaker Various - but mostly feeders to plant
transformers
Year of manufacture of circuit breaker 1976
Years of operation since first commissioning 36-40 years
Manufacturer Siemens
Serial numbers 31175637
Type of operating mechanism Manual operating mechanism
Type of bodywork Trolley
Control voltage (DC/AC) DC
Control voltage 110 V
Motor voltage (DC/AC) DC
Motor voltage 110 V
Number of operations in accordance with the operation counter low
Diagnosis Bad, big impact deficiencies
Remark mechanisms sliding surfaces are
rusted and no longer support smooth
operation affecting the closing and
tripping speeds of the mechanisms

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Second type of circuit breaker
Are circuit breakers installed? Yes
Principle of interruption Vacuum
Number of circuit breakers 3
Type designation of circuit breaker Siemens 3AC & 3TL5
Year of manufacture of circuit breaker 1976
Years of operation since first commissioning 36-40 years
Manufacturer Siemens
Serial numbers as per individual breakers
Type of operating mechanism Magnet drive
Type of bodywork Trolley
Control voltage (DC/AC) DC
Control voltage 110 V
Number of operations in accordance with the operation counter N.A.
Diagnosis Bad, big impact deficiencies
Remark corrosion affecting contactors in
similar ways as circuit breakers with
the smooth surfaces showing
corrosion making these surfaces rough
and slowing down contactor mag coil
open and close operations-this is a
common and general problem on all
equipment
Third type of circuit breaker
Are circuit breakers installed? No but accessories

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First type of load break switch
Are load break switches or fuses installed? Yes
Design Fuse mounting
Type of operating mechanism Manual operating mechanism
Number of load-break switches none (fitted are only fuses with striker
pin mounting brackets on all contactor
feeders)
Type designation of load break switch none
Year of manufacture of load-break switch none
Years of operation since first commissioning 36-40 years
Manufacturer Siemens
Serial numbers not visible on all
Control voltage (DC/AC) DC
Control voltage Other...
Which kind of control voltage? 30V DC
Number of operations in accordance with the operation counter Indeterminable
Diagnosis Bad, big impact deficiencies
Remark corrosion
Second type of load break switch
Are load break switches or fuses installed? No
First type of disconnector
Are disconnectors installed? No
First type of earthing switch
Are earthing switches installed? Yes – however internal behind rear
Make proof earthing switch Yes
Type of operating mechanism Manual operating mechanism
Number of earthing switches not determinable
Type designation of earthing switch cable earth switches if fitted
Year of manufacture of earthing switch same as panel
Manufacturer Other...
Manufacturer Siemens Italy
Serial numbers not determinable

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Second type of earthing switch
Are earthing switches installed? No
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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Current transformer incoming feeder
Are current transformers installed? Yes
Design Post insulator instrument transformer
Insulation Cast resin
Type Current Electric
Year of manufacture assumed same as panel
Manufacturer Current Electric
Quantity several spread out among feeders,
incomers, etc.
Serial numbers Name plates are taped to the LT
compartment walls
Core data of 1st core (Example: 200/1 A, 15 VA, 5 P 20) as plates
Core data of 2nd core (Example: 200/1 A, 15 VA, 5 P 20) as plates
Core data of 3rd core (Example: 200/1 A, 30 VA, 1 Fs 5) as plates
Core data of 4th core (Example: 200/1 A, 15 VA, 5 P 20) as plates
Diagnosis Medium, insignificant deficiencies
Condition of current transformers Very dirty
Remark the panels could be cleaned on in situ
on site & re-insulated, treated and
cleaned and re-painted
Current transformer outgoing feeder
Are current transformers 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
Over voltage limiter
Are overvoltage limiters 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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Over current protection
Over current protection Yes
Manufacturer Other
Manufacturer various
Type Over current & Earth fault
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
Busbar protection
Busbar protection No
Low voltage switchgear
Are low voltage switchgear installed? Yes
Manufacturer various
Type LV 400V Isolators & feeder circuit
MCB's
Year of manufacture unknown
Personnel protection insulation in accordance with DIN VDE 0106 (IEC
60990)
No
Diagnosis Bad, big impact deficiencies
Remark Safety PPE like 1kV Electrical
insulated gloves and specially
insulated tools need to be available for
the staff, including all panel electrical
documentation on LV & MV
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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Compressed air generation
Is a compressed air generation available? No
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
Personnel protection insulation DIN VDE 0106 (IEC 60990)
- The located weakpoints regarding personnel protection insulation have to be removed immediately
Operational safety DIN VDE 0101 (IEC 61936)
- The located weakpoints have to be removed immediately
Natural Ageing
- The actual ambient conditions may require additional maintenance works
Condition of building
outside
- The located weakpoints on the building have to be removed immediately
inside
- The located weakpoints on the building have to be removed immediately
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
First type of load break switch
- Maintenance of operating mechanism.
Post insulators
- Maintenance of insulators.

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Bushings
- Maintenance of insulators.
Busbars
- Maintenance of insulators.
Current transformer
Current transformer incoming feeder
- Maintenance of the equipment
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.