Power Systems Substations Service

Rak White Cement

RAK White Cement
Annex I - Assessment Report

Power Systems Substations: Doc. name: RAK White Cement

Status of
Product: Substation Assessment document: Draft
Issued by
department: Substation Service Project name: Rak White Cement

Date: 11/21/2015 Doc. type: Technical

Lang.: English Creator name: S.S

Revision: 18 Distribution: ABB - RAK White Cement

Pages: 21
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Annex I - Assessment Report

Table of contents
1 Introduction ___________________________________________________________ 3
1.1 Assignment ........................................................................................................................... 3
1.2 Assessment policy ............................................................................................................... 3
2 Risk assessment _______________________________________________________ 4
2.1 Primary Equipment MV ........................................................................................................ 4
2.1.1 Disconnect Switch ............................................................................................................................. 4
2.1.2 Circuit Breaker (Drawout) .................................................................................................................. 6
2.1.3 Distribution Transformer .................................................................................................................. 12
2.2 Secondary Equipment........................................................................................................ 19
2.2.1 Protection Relay .............................................................................................................................. 19

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1 Introduction

1.1 Assignment
ABB Substations has on behalf of RAK White Cement carried out a substation analysis of RAK White Cement.

1.2 Assessment policy

Substation assessment is a visual inspection that provides a comprehensive risk assessment, which is based on
the following criteria:
1. International normative standards,
2. ABB's accumulated experience as a developer, manufacturer and supplier of equipment and systems for
electrical infrastructure.
The assessment is presented by types of equipment plotted in a chart with condition / importance on x / y axis.

Condition is assessed by ABB’s inspector as a value between 0 and 100, where 0 is best and 100 is poorest.
The reliability analysis of the substation allows us to calculate the components importance according to its
contribution to the outage rate of the loads. Customer feedback is considered for the validation of the components
importance. The importance is defined as a value between 0 and 100, where 0 is lowest and 100 is highest.
Eventually each component is defined as a coordinate with a calculated distance from the origin, 0-100, which
also represents the risk-factor – 0 for lowest and 100 for highest risk.

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2 Risk assessment

2.1 Primary Equipment MV

2.1.1 Disconnect Switch

General Conclusions
The following shall always be considered:
• Contacts exposed to air, i.e. particularly sensitive to ambient conditions, e.g. salt, pollution, etc.
• Lubrication condition of contacts, drive and linkage system, using correct grease
The switches are in acceptable condition. But test measures the resistance at the micro- or milli-ohm level of the
contact to be done primarily to verify that electrical connections are made properly, and to detect the following
problems:
• Loose connections
• Adequate tension on bolted joints
• Eroded contact surfaces
• Contaminated or corroded contacts
This is particularly important for contacts that carry large amounts of current (e.g. switchgear busbars) as higher
contact resistance leads to higher losses and lower current carrying capacity.

Assessment Result

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Component Ranking
Showing only those component with higher risk than 43%.
Designation Model Manufacturer Year Cond. Imp. Risk

DESALINATION Air Switch-disconnector NAL ABB 1995 57.31 91.70 74.50

2 - Q1

DESALINATION Air Switch-disconnector NAL ABB 1995 57.31 91.70 74.50

2 - Q2

INCOMER 2 - Air Switch-disconnector NAL ABB 1995 57.31 91.70 74.50

Q2

INCOMER 2 - Air Switch-disconnector NAL ABB 1995 57.31 91.70 74.50

Q1

INCOMER 4 Air Switch-disconnector NAL ABB 1995 57.31 91.70 74.50

SPARE - Q1

INCOMER 3 - Air Switch-disconnector NAL ABB 1995 57.31 91.70 74.50

Q2

INCOMER 3 - Air Switch-disconnector NAL ABB 1995 57.31 91.70 74.50

Q1

INCOMER 4 Air Switch-disconnector NAL ABB 1995 57.31 91.70 74.50

SPARE - Q2

INCOMER - Q1 Air Switch-disconnector NAL ABB 1995 57.31 91.70 74.50

INCOMER - Q2 Air Switch-disconnector NAL ABB 1995 57.31 91.70 74.50

SS LSSNo.1A - Air Switch-disconnector NAL ABB 1995 57.31 91.70 74.50

Q1

SS LSSNo.1A - Air Switch-disconnector NAL ABB 1995 57.31 91.70 74.50

Q2

SS LSS No.2A - Air Switch-disconnector NAL ABB 1995 57.31 91.70 74.50
Q1

SS LSS No.2A - Air Switch-disconnector NAL ABB 1995 57.31 91.70 74.50
Q2

SPARE - Q1 Air Switch-disconnector NAL ABB 1995 57.31 91.70 74.50

SPARE - Q2 Air Switch-disconnector NAL ABB 1995 57.31 91.70 74.50

SPARE 3 - Q1 Air Switch-disconnector NAL ABB 1995 57.31 91.70 74.50

SPARE 3 -Q2 Air Switch-disconnector NAL ABB 1995 57.31 91.70 74.50

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Designation Model Manufacturer Year Cond. Imp. Risk

SPARE 1 - Q1 Air Switch-disconnector NAL ABB 1995 57.31 91.70 74.50

SPARE 1 - Q2 Air Switch-disconnector NAL ABB 1995 57.31 91.70 74.50

Recommendations

General:
SR Switchgear - Indoor Air Switch-disconnector, NAL/NALF/VR Rated voltage: 12kV, Disconnector ABB
made 1990 -1995.

Apart from aging, access to documentation is limited and spare parts are no longer available.

Risk exposure Consequence

Nothing in particular reported. » -

Recommendation:
Initiate a replacement program or perform maintenance with 1 years interval; lubrication, measuring contact
resistance, exercising.
Moving and fixed contacts are greased with – ISOFLEX TOPAS NCA 52
Replacement should take place when:
• The tip of the arcing contact knives has diminished approx. 3 mm (by minor damage might only cause
polishing of the arcing tip),
• The fixed arcing fingers are burned or do not make any contact,
• The width of the slot in the arcing chamber is more than 8 mm. If the cooper is visible on any current bus
part, then this part should be replaced by new one.
Electrical Maintenance Tests:
• Test insulation resistance for all phases to others and to ground.
• Test contact resistance across switch blade contact surfaces.
• Test electrical charging mechanism of switch if applicable.
• Test electrical interlocks for proper function.
• Operate blown fuse trip devices if applicable.

2.1.2 Circuit Breaker (Drawout)

General Conclusions
The following shall always be considered:
• Operation frequency, the number of fault clearances and the aggregated size of the fault currents
• Lubrication condition of contacts, drive and linkage system, using correct grease

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Periodic inspections and maintenance are essential to obtain safe and reliable operation of the circuit breaker.
When circuit breakers are operated under “Usual Service Conditions”, maintenance and lubrication is
recommended at ten year intervals or at the number of operations indicated. “Usual” and “Unusual” service
conditions for Medium Voltage metal-Clad Switchgear (includes Circuit Breaker Module) are defined in ANSI
C37.20.2, section 8.1. Generally, “usual service conditions” are defined as an environment in which the equipment
is not exposed to excessive dust, acid fumes, damaging chemicals, salt and air, rapid or frequent changes in
temperature, vibration, high humidity, and extremes of temperature. The definition of “usual service conditions” is
subject to a variety of interpretations. Because of this, you are best served by adjusting maintenance and
lubrication intervals based on your experience with the equipment in the actual service environment. Regardless
of the length of the maintenance and lubrication interval, ABB recommends that circuit breakers should be
inspected and exercised annually.
The circuit breakers are in acceptable condition and there was no maintenances done. Nonetheless, they are
imposing a risk on substation due to the following:
1. 7.2kV circuit breakers Rotary Arc are obsolete and the manufacturer Yawaksa no more manufacturing this
breakers, i.e. neither support nor no spare parts available
2. 36kV circuit breakers Unigear Z1 (Non-ABB Install) that needs a 2 incoming circuit breaker. The current
situation, the whole plant is supplied directly from FEWA 1 and FEWA 2 to the transformer without an incomer
circuit breaker at the 36kV (HV Side) at RAK White cement. If there's short circuit fault either on the cable or an
internal fault on the transformer this will always trip the breaker on FEWA side.
Consequently, we strongly recommend RAK White Cement to consider the following:
• Install new incomer Circuit Breaker through retrofit solution
TRANCO S/S CKT1 H-24
TRANCO S/S CKT2 H-35
• Replace of Rotary Arc Circuit Breakers
o Initiate a replacement program:
Replace circuit breakers – retrofit by means of new breaker and new modern mechanism

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Assessment Result

Component Ranking
Showing only those component with higher risk than 43%.
Designation Model Manufacturer Year Cond. Imp. Risk

INCOMER 4 ABB VD4M 1212-25 ABB 1995 43.59 91.70 67.64

LINE 1 PS - Q0

DESALINATION ABB VD4M 1212-25 ABB 1995 43.59 91.70 67.64

2 - Q0

INCOMER 2 - ABB VD4M 1212-25 ABB 1995 43.59 91.70 67.64

Q0

SS LSSNo.1A - ABB VD4M 1212-25 ABB 1995 43.59 91.70 67.64

Q0

SS LSS No.2A - ABB VD4M 1212-25 ABB 1995 43.59 91.70 67.64
Q0

SPARE 2 - Q0 ABB VD4M 1212-25 ABB 1995 43.59 91.70 67.64

SPARE 3 - Q0 ABB VD4M 1212-25 ABB 1995 43.59 91.70 67.64

INCOMER 3 - ABB VD4M 1212-25 ABB 1995 43.59 91.70 67.64

Q0

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Designation Model Manufacturer Year Cond. Imp. Risk

INCOMER - Q0 ABB VD4M 1212-25 ABB 1995 43.59 91.70 67.64

SPARE 1 - Q0 ABB VD4M 1212-25 ABB 1995 43.59 91.70 67.64

DESAL 1 - Q0 6E25BB/M Yaskawa's 1984 47.86 85.98 66.92

Switchgear

GTG AUX2 - Q0 6E25BB/M Yaskawa's 1984 47.86 85.98 66.92

Switchgear

LSS3 - Q0 6E25BB/M Yaskawa's 1984 47.86 85.98 66.92

Switchgear

LSS4 - Q0 6E25BB/M Yaskawa's 1984 47.86 85.98 66.92

Switchgear

LSS1 - Q0 6E25BB/M Yaskawa's 1984 47.86 85.98 66.92

Switchgear

LSS2 - Q0 6E25BB/M Yaskawa's 1984 47.86 85.98 66.92

Switchgear

PT/LA1 - Q0 6E25BB/M Yaskawa's 1984 47.86 85.98 66.92

Switchgear

BSAUX - Q0 6E25BB/M Yaskawa's 1984 47.86 85.98 66.92

Switchgear

GTG AUX1 - Q0 6E25BB/M Yaskawa's 1984 47.86 85.98 66.92

Switchgear

PT/LA2 - Q0 6E25BB/M Yaskawa's 1984 47.86 85.98 66.92

Switchgear

LSS5 - Q0 6E25BB/M Yaskawa's 1984 47.86 85.98 66.92

Switchgear

LSS1 R Q0 6E25BB/M Yaskawa's 1984 47.86 85.98 66.92

Switchgear

LSS2 R Q0 6E25BB/M Yaskawa's 1984 47.86 85.98 66.92

Switchgear

STNSER - Q0 6E25BB/M Yaskawa's 1984 47.86 85.98 66.92

Switchgear

GT AUX3 - Q0 P34020-999-54 Yaskawa's 1984 47.86 85.98 66.92

Switchgear

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Designation Model Manufacturer Year Cond. Imp. Risk

GT AUX4 - Q0 6E25BB/M Yaskawa's 1984 47.86 85.98 66.92

Switchgear

SPARE-2 Q0 6E25BB/M Yaskawa's 1984 47.86 85.98 66.92

Switchgear

RC CBC 1 - Q0 6E25BB/M Yaskawa's 1984 47.86 85.98 66.92

Switchgear

RC CBC 2 - Q0 6E25BB/M Yaskawa's 1984 47.86 85.98 66.92

Switchgear

SPARE - 3 Q0 6E25BB/M Yaskawa's 1984 47.86 85.98 66.92

Switchgear

SPARE-1 Q0 6E25BB/M Yaskawa's 1984 47.86 85.98 66.92

Switchgear

Recommendations

General:
VD4M circuit breaker of puffer principle manufactured by ASEA/ABB 1993-2002. Withdrawable design with
integrated spring gear.
Good access to expertise and access to spare parts. Retrofit units are not available.
Initiate and replacement program or Maintenance of the VD4M.

Risk exposure Consequence

Nothing in particular reported. » -

Recommendation:
Maintenance of the VD4M as stated below;
Checks of the primary power path
• Cleanliness check
• Inspection of flexible connectors
Checks of the stored energy operator mechanism
• Maintenance and lubrication
• Fastener check
• Manual spring charging check
• Contact erosion check
• Electrical control checks
• Wiring and terminals check
• Secondary disconnect check

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• Automatic spring charging check

• Electrical close and trip check
• Vacuum integrity check
• High potential test
• Insulation test
• Contact resistance test
• Inspection and cleaning of circuit breaker insulation
• Functional tests

General:
Yaskawa's Electric - Indoor Rotary Arc Circuit Breaker, SF6 Rated voltage: 7.2kV, Disconnector Kitakyushu
made 1984.
Apart from aging, access to documentation is limited and spare parts are no longer available.

Risk exposure Consequence

Nothing in particular reported. » -

Recommendation:
Maintenance to be carried out:
• Checking operation Time interval Criteria
• Carry out five mechanical opening closing operations - The circuit-breaker must operate normally without
stopping in intermediate positions.
• Visual inspection of the poles (parts in resin) - The parts in resin must be free of any accumulation of dust,
dirt, cracks, discharges or traces of surface discharges.
• Visual inspection of the operating mechanism and transmission - The elements must be free of any
deformation.
• Screws, nuts, bolts, etc. must be tight.
• The isolating contacts must be free of any deformation or erosion.
• Lubricate the contact elements
• Measuring the insulation resistance.
• Checking interlock operation.
• Manual spring charging check
• Contact erosion check
• Electrical control checks
• Wiring and terminals check
• Secondary disconnect check
• Electrical close and trip check

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• SF6 leakage
• Measuring of contact resistance check

As per requirement from RAK White Cement to use ABB Switchgear for the increase of load from 5.5MW to 4.5
MW for the new project. Whereby ABB recommendation as stated below;
Plant load has to be divided on two bus bars (6.6kV) operating in islanding (means two separate network),
existing bus bar 1000A can feed the partial loads of the plants. If to parallel the two BB at ABB switchgear in
order to increase the ampacity to 2000 A then for a fault in ABB switchgear BB the two main transformers will
be feeding the fault and the actual fault current will be exceeding the withstand capacity.

1) With existing SWG (two bus bars operating in island)

o Existing double bus system if operated in island (no parallel operation of bus bars) can take partial
loads (can be limited up to 6.5MW for one bus).
o However, a short circuit study considering future loads’ characteristics/fault contribution shall be
carried out to determine actual levels and perform relay settings & coordination (considering new
relays, new operating configuration and loads).
2) With existing SWG (bus bars operated in parallel)
For this configuration there are two possibilities a) Fed by 1 x 15MVA transformer & b) Fed by 2 x 15MVA
transformer (in parallel)
For a)
o All bus isolators Q1 & Q2 should be kept closed
o The two bus will share the 10MW load equally (as all Q1 & Q2 are closed).
o Short circuit calculations should be done with future loads’ contribution to see if the actual fault level
remains within 25kA. Chances are that with 1 Trafo it will remain below 25kA.
o Protection settings need to be revised.
For b)
o Same as for a) but with 2 x 15MVA transformers in operation.
o In this case the fault level will be above 25kA and SWG will be at risk.
o Solution introduce Is limiter or fused switches at Incomer but not recommended as discrimination
with outgoing feeders’ protection will be a problem.
3) Replace the existing 6.6kV SWG with new SWG (sized/designed according to client’s future
plans)

2.1.3 Distribution Transformer

General Conclusions
The following shall always be considered regardless of brand and type of power transformers:
• Perform regularly dissolved gas analysis and oil condition tests for fast identification and correction of
emerging problems. The oil sample and analysis has been performed by RAK White cement.

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• The transformer's temperature, that if too high inevitably will shorten its lifetime. In this context, rated power
versus operational loading and an effective cooling system are of utmost importance.

• Heater in control boxes shall always be in operation to prevent condensation and corrosion.

• The tap changer’s drying agent. If the soot that is produced naturally at tap switching becomes humid, a
conductive coating may be formed, which in turn may cause internal arcing.

• Due to the sealed design, it was difficult to properly inspect the transformers but through the maintenance
program it is likely to assume that situation is under control.
However, we recommend RAK White cement to consider the following:
Verify condition by examining maintenance test history and comprehensive condition monitoring is require by
means of measurements e.g. winding resistance, Tan δ, diagnostic of condition of OLTC, insulation resistance
etc.
DGA Report analysis which perform by RAK White cement
The two principal causes of gas formation within an operating transformer are electrical disturbances and thermal
decomposition. All transformers generate gases to some extent at normal operating temperatures. Insulating
mineral oils for transformers are mixtures of many different hydrocarbon molecules, and the decomposition
processes for these hydrocarbons in thermal or electrical faults are complex. The fundamental chemical reactions
involve the breaking of carbon hydrogen and carbon-carbon bonds. During this process, active hydrogen atoms
and hydrocarbon fragments are formed. These fragments can combine with each other to form gases: hydrogen
(H2), methane (CH4), acetylene (C2 H2), ethylene (C2 H4), and ethane (C2 H6). Further, when cellulose
insulation is involved, thermal decomposition or electric faults produce methane (CH4), hydrogen (H2), carbon
monoxide (CO), and carbon dioxide (CO2). The gases listed above are generally referred to as key gases. The
gases listed above are considered key gases and are generally considered combustible (note that CO2 is not a
combustible gas). The total of all combustible gases may indicate the existence of any one or a combination of
thermal, electrical, or corona faults. The rate at which each of these key gases are produced depends largely on
the temperature and directly on the volume of material at that temperature. Because of the volume effect, a large,
heated volume of insulation at moderate temperature will produce the same quantity of gas as a smaller volume
at a higher temperature.
Therefore, the concentrations of the individual dissolved gases found in transformer insulating oil may be used
directly and trended to evaluate the thermal history of the transformer internals to suggest any past or potential
faults within the transformer.
Basically, any sharp increase in key gas concentration is indicative of a potential problem within the transformer.
Below is a table which has been derived from ANSI/IEEE C57.104-2008 information. The suggested action
levels for key gas concentrations are also provided:

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Where DGA results include a sharp increase in key gas concentration levels and/or normal limits have been
exceeded. As key gas concentration levels approach the action levels, consideration should be given to taking
the transformer out of service for further testing and inspection.
DGA Report Anaysis results explanation
IEEE Recommendations 57.104-2008
• Gases Produced Due to Overheating and Extreme Overheating of Mineral Oil

o FEWA 1 TR1
Condition 3 (C2H6, CO2)
o FEWA 2 TR2
Condition 2 (H2, C2H6, CO2)
o LINE 3 RAW MILL TRN
Condition 4 (C2H4, CO2)
Definition of Gases
• C2 H6 – Ethane
o Ethane is produced when a point source of heat raises the oil at the source to 400 ⁰C or 750⁰
level of heat begins to damage the paper very quickly. Over a period of time, the insulation level of a
piece of equipment will degrade to a point where the insulation becomes very brittle and, if subjected
to strong forces that tend to move the windings such as a close in fault, will short circuit the windings
and cause catastrophic failure. High levels of Ethane, coupled with rate of rise, should be predominant
factors in determining when a unit will be pulled from service and electrical tests performed on the
insulation strength and dielectric ability.
• C2 H4 - Ethylene

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o Ethylene is produced when a point source of heat reaches 600 ⁰C or 108

hot enough to melt copper. Problems like no load tap changers and winding strand-to-strand failure
produce Ethylene. At this point there is a serious problem in the unit. Any substantial rate of rise
should be an alarm condition and immediate plans should be made to remove the unit from service.
Ethylene formed in a load tap changing compartment such as an LTC presents another problem. An
LTC compartment should be at ambient temperature most of the time. Any heat sources high enough
to generate Ethylene will also melt the contacts and form coke, a form of carbon and a by-product of
the oil, on the contacts. This coke adds to the problem and soon causes blinking or no light calls. The
coke acts as an insulator and, in electrical terms, acts the same as a carbon film resistor. The coke
limits the amount of arcing that will take place in a tap changer or breaker, but at the same time will
absorb the energy released by the arc and convert it to heat. The accumulation of coke retains the
heat, ultimately destroying the contacts and possible the unit.
DGA can be applied to the main tank of transformers or regulators
The tap changing under load takes place. In the main tanks of transformers and regulators, small quantities of
low order hot metal gases are common. As the load increases, the winding temperature raises to a point at which
gases such as Butane and Propane are generated. These gases are not tracked. As the heating continues to
above 100 ⁰C, Metha
temperatures generate Ethane and Ethylene, as described earlier. When large amounts of these gases are
generated or the rate of rise is high, an investigation should be conducted to find the cause. Hydrogen can be
produced in two unique circumstances. The first is because of Partial Discharge taking place in the main tank.
This low energy discharge from metal to metal or oil to metal causes Hydrogen to be released from the oil and
redeposit as a gas. The second reason is high moisture in the oil. The moisture decreases the dielectric of the oil
to a point where current leakage through the oil again causes Hydrogen to be released. Additionally, the water
breaks down into its basic components of Hydrogen and Oxygen, therefore increasing the Oxygen in the unit as
well as adding to the Hydrogen. Any time Hydrogen is being produced, a check for CO2 and CO should be made
to check on insulation damage. This is not an absolute check for insulation damage, but merely one type of
indicator.
Harmonic
The other cause of heat could be due to harmonics if the load are control by variable speed drives such mill motor,
Force draught fan and cooler drives etc.

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Infrared Camera Results

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Assessment Result

Component Ranking
Showing only those component with higher risk than 43%.
Designation Model Manufacturer Year Cond. Imp. Risk

TR1 - FEWA L1 MF MF Transformatoria 2009 69.94 77.95 80.86

srl

TR2 - FEWA L2 MF MF Transformatoria 0 69.94 77.95 74.85

srl

TRA1 ABB Electrical 1995 81.77 78.41 88.53

Industri LTD

Recommendations

General:
FEWA 1 TR1 - Oil-immersed 3 Phase - 2 winding transformer produced by MF Transformatoria srl 2009. Tap
changer, type UBBLT200/400 produced by ABB.
Good access to expertise and spare parts.

Risk exposure Consequence

The transformer's temperature high. Shorten its lifetime - In this context, rated power
Maintenance was not performed
» versus operational loading and an effective cooling
system are of utmost importance.

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DGA Analysis - Condition 3 (C2H6, CO2) Gases Produced Due to Overheating and Extreme
Overheating of Mineral Oil - heating or discharge
damages enough insulation, an arc begins. This
arc not only carries voltage, but can support
current as well. This is the final phase of failure.

Recommendation:
Initiate a maintenance program.
• The preliminary test will be carried on the transformers to assess the integrity of connections, moisture in
paper insulating material etc.
• The oil level will be lowered to verify the inside bushing connections, tap changer connections etc
• Drained oil will be filled back and filtered to get dielectric value of above 70KV
• Removal of dust, dirt and debris from the external enclosure surfaces mainly in any coolant path will be
cleaned by using steam washing machine.
• The oil sample (one sample per transformer) will be taken finally from the transformer bottom valve and
analyses for water content, tan delta & DGA
• The electrical tests will be carried out before and after internal inspection.

General:
FEWA 2 TR2 - Oil-immersed 3 Phase - 2 winding transformer produced by MF Transformatoria srl 2009. Tap
changer, type UBBLT200/400 produced by ABB.
Good access to expertise and spare parts.

Risk exposure Consequence

The transformer's temperature high. Shorten its lifetime - In this context, rated power
versus operational loading and an effective cooling
Maintenance was not performed
system are of utmost importance.
DGA Analysis - Condition 2 (H2, C2H6, CO2)
» Gases Produced Due to Overheating and Extreme
Overheating of Mineral Oil - heating or discharge
damages enough insulation, an arc begins. This
arc not only carries voltage, but can support
current as well. This is the final phase of failure.

Recommendation:
Initiate a maintenance program.
• The preliminary test will be carried on the transformers to assess the integrity of connections, moisture in
paper insulating material etc.
• The oil level will be lowered to verify the inside bushing connections, tap changer connections etc.
• Drained oil will be filled back and filtered to get dielectric value of above 70KV
• Removal of dust, dirt and debris from the external enclosure surfaces mainly in any coolant path will be
cleaned by using steam washing machine.
• The oil sample (one sample per transformer) will be taken finally from the transformer bottom valve and

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Annex I - Assessment Report

analyses for water content, tan delta & DGA

• The electrical tests will be carried out before and after internal inspection.

General:
RAW MILL TRA1 - Oil-immersed 3 Phase - 2 winding transformer produced by ABB 2009.
Good access to expertise and spare parts.

Risk exposure Consequence

The transformer's temperature high. Gases Produced Due to Overheating and Extreme
Overheating of Mineral Oil - heating or discharge
Maintenance was not performed
» damages enough insulation, an arc begins. This
DGA Analysis - Condition 4 (C2H4, CO2) arc not only carries voltage, but can support
current as well. This is the final phase of failure.

Recommendation:
Initiate a maintenance program.
• The preliminary test will be carried on the transformers to assess the integrity of connections, moisture in
paper insulating material etc.
• The oil level will be lowered to verify the inside bushing connections, tap changer connections etc.
• Drained oil will be filled back and filtered to get dielectric value of above 70KV
• Removal of dust, dirt and debris from the external enclosure surfaces mainly in any coolant path will be
cleaned by using steam washing machine.
• The oil sample (one sample per transformer) will be taken finally from the transformer bottom valve and
analyses for water content, tan delta & DGA
• The electrical tests will be carried out before and after internal inspection.

2.2 Secondary Equipment

2.2.1 Protection Relay

General Conclusions
The following shall always be considered:
· Access to complete set of updated documentation, to facilitate troubleshooting and maintenance · Proper
supervision of key functions, e.g. trip circuits, fuse failure, auxiliary DC-supply etc.
· Relay cubicles – doors closed, proper labeling, cable seals, fire seals and adequately grounded
· Separate auxiliary DC-supply, not being shared with other circuits, e.g. indication and control etc.
· Located in air conditioned room, +20 ⁰C, with p
of soot, dust, pollution etc.

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Annex I - Assessment Report

· Proper seals in panels to i) limit consequences in the event of fire, ii) prevent animals to enter Although the
system is in rather good condition from a strict functional point of view, the following findings emphasize need to
take preventive actions:
1. Many of the protection relays are obsolete, e.g. MCGG, MTVU
2. Rak White cement does not have spare parts in stock
Consequently, we strongly recommend RAK White Cement to consider the following:
· Initiate a modernization program in order to i) substantially enhance the possibilities of post-fault analysis and ii)
optimize maintenance resources, by replacing all existing obsolete protection relays with one modern numerical
protection system, i.e. Intelligent Electronic Devices (IED).

Assessment Result

Component Ranking
Showing only those component with higher risk than 43%.
Designation Model Manufacturer Year Cond. Imp. Risk

MCGG MGCC Alstom 1982 72.58 91.70 82.14

MTUV MVTU Alstom 1988 66.90 91.70 79.30

Recommendations

General:

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unauthorized use, reproduction, distribution or disclosure to third parties is strictly forbidden. ABB reserves Page 20 of 21
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 Rak White Cement

RAK White Cement

Annex I - Assessment Report

Static electronic 82 Overcurrent Relay for Phase and Earth Faults protection produced by Alstom 1982 -
1995.
Limited access to expertise and no access to replacement modules.

Risk exposure Consequence

• Fatigue of DC-supply modules • Loss of operation
• Age-related deterioration of printed circuit boards, » • Malfunctioning due to instability and/or loss of
e.g. measurement modules etc. operation

Recommendation:
< 25 years
Perform functional testing: every 4 years, 2 years if no redundant protection exist. Monitor carefully tendency
of deteriorating modules
> 25 years
Replace with modern protection IEDs (Intelligent Electronic Device)

General:
Static electronic Type MVTU Definite Time Delayed Relays protection produced by Alstom 1990-2000

Limited access to expertise and limited access to replacement modules.

Risk exposure Consequence

• Fatigue of DC-supply modules • Loss of operation
• Age-related deterioration of printed circuit boards, » • Malfunctioning due to instability and/or loss of
e.g. measurement modules etc. operation

Recommendation:
Replace with modern protection IEDs (Intelligent Electronic Device)

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unauthorized use, reproduction, distribution or disclosure to third parties is strictly forbidden. ABB reserves Page 21 of 21
all rights regarding Intellectual Property Rights.