Abu Rdis – Potential Transformer Damage

Observation Report
Rev 00
22/03/2022

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Contents

Product and Site Info.....................................................................................................................................3

Incident Description......................................................................................................................................3
SLD..................................................................................................................................................................4
Containment Actions.....................................................................................................................................5
Corrective Actions.........................................................................................................................................5
Observations...................................................................................................................................................5
Protection Relay Extracts...........................................................................................................................14
Recommendations........................................................................................................................................23
Additional Recommendations.....................................................................................................................23
Conclusion....................................................................................................................................................25

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Product and Site Info
Product type MCset 1,2,3
Panel ID Cell 01 / Incoming Feeder
Order No. / Item No. E114011.02 / Item 3/4
Rated voltage 2.1 KV
Rated current 1250 A
Customer Petrobel
Affected site SS 80 – Balayim New Prefabricated Cabinet
Location Abu Rdis – Red Sea

Incident Description
- Customer informed SEE that a crack occurred on the Potential Transformer of
What happened Phase L2 for Cell 1/Main Incomer 1.

Where Cell 01 – Main Incomer – Potential Transformer for Phase L2

When Most probably 19/03/2022 according to disturbance records extracted
Who detected Substation Operation Team.
How detected Sepam & voltmeter measurements weren’t similar to phases L1&L3. (Pic 13)
How many One cell – Main Incomer – Cell 01

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SLD

PT failure Ph-L2

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Containment Actions
 As a fast containment action, our site-team has conducted a troubleshooting visit at the customer’s
site on March 21th in order to assess the damage and collecting the needed data.
 We replaced the 3 P.Ts (ALCE type) with the spare ones until the full assessment for the
previously installed PTs as the customer kept using this cell since the occurrence of the failure.
 We extracted the protection relays setting from the installed Sepams for detailed analysis.
 We asked the customer to activate all the voltage protection functions for all the incomings existing
in the substation.
 We asked the customer to provide us with the voltage wave form of upstream ss (generation ss).

Corrective Actions
 All collected data along with the defected potential transformer (ALCE type) will need to be sent
for TEX analysis.
 The defected P.Ts (ALCE type) will be sent back to BADR for full assessment.

Observations
1- Failure occurred at cell 01 – Main Incomer affecting Potential Transformer of Phase L2.
(Pic 6,7,8 &9)
2- After dismantling the affected P.Ts, the subjected potential transformer (ALCE type)
appeared severely cracked. (Pic 6,7,8 &9)
3- Voltage protection functions were deactivated by customer.
4- Too much dust inside shelter and inside panels as well. (Pic 3,4 & 5)
5- The copper connection for phase L2 is decoloured most probably because of the humidity
and the dust. (Pic 10)

Important Observation:

1- Customer claims that the voltage protection functions were deactivated since the
commissioning of the substation.
2- According to the above point, we couldn’t find any valuable data that could help analyse this
failure within the extracted log from the protection relay.
3- We asked the customer to obtain the protection relay’s extractions (events log &
disturbance record) for the upstream SS.
4- The new P.Ts weren't stored properly. (Pic 11&12)
5- The shelters aren't sealed properly and the dust affects the mechanical operation of the
shutters and the circuit breakers. (Pic 3,4 & 5 &15)
6- The roof of the shelter needs to be repaired and installed correctly. (Pic 16)

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Pic.1 Item 1 name plate Pic.2 Cell 1 overview

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Pic.3 Existing dust behind the installed cells Pic.4 Existing dust inside the shelter

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Pic.5 Existing dust inside the cells Pic.6 L2 cracked potential transformer

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Pic.7 Potential transformer name plate Pic.8 Cracked Potential transformer after dismantling

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Pic.9 Affected Potential Transformer Pic.10 Decoloured copper connection for phase L2.

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Pic.11 Existing dust on the new P.Ts (Bad Storage) Pic.12 Existing dust on the new P.Ts (Bad Storage).

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Pic.13 Errored voltage measurement on the Pic.14 Site enviroment.
voltmeter

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 Existing dust on the
roofs of the cells

Shelter Roof needs to

be repaired

Pic.15 Existing dust on the roof of the switchgear Pic.16 Shelter Roof.

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Protection Relay Extracts

 ITEM 3/4 – Incomer – Cell 1

1- Setting overview
i. General characteristics VT connection type to be
checked, should be V1, V2, V3

Residual voltage measurement

should be none

ii. Current protection

50/51 activated
Elements 1 & 2

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 50N activated
Element 1

iii. Voltage protection

-All voltage protections

were deactivated
27,59 & 59N

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 2- Disturbance recorder overview

1
-On 19/03/2022 2:33:21 AM, there’s an OC happened.
-short circuit duration is about 190 ms, less than OC and EF settings, that’s why
CB not tripped.
-fault current was about 5KA then decayed to normal value 190 A

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 2

2
-A disturbance at voltage measurement was occurred before current fault for a
period 400 ms (incident of PT failure)
-After current back to normal value, voltage measurements were
U21= 1.2KV
U32= 1.2KV Failure at Ph-L2
U13= 2.1KV

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  ITEM 2/2 - Up stream– Incomer – Cell 3

1- Setting overview
i. General characteristics

VT connection type and

residual voltage
measurement should be
revised

ii. Current protection

-50/51 activated for elements

1,2&3

-50N activated for element 1

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 iii. Voltage protection

-All voltage protections were

deactivated

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 2- Disturbance recorder overview

-On 19/03/2022 2:21:09 AM, there’s an OC happened.

-short circuit duration is about 190 ms, less than OC and EF settings, that’s why
CB not tripped.
-fault current was about 1KA then decayed to normal value 98.4 A
-time is not the same at all protection relays. (Time not synched)

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  ITEM 2/2 - Up stream– Outgoing – Cell 1

1- Setting overview
i. Current protection

-50/51 activated for elements

1,2&3

-50N activated for element 1

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 2- Disturbance recorder overview

-On 19/03/2022 2:28:56 AM, there’s an OC happened.

-short circuit duration is about 190 ms, less than OC and EF settings, that’s why
CB not tripped.
-fault current was about 1KA then decayed to normal value 46 A
-time is not the same at all protection relays. (Time not synched)

Conclusion

 Voltage protection functions were not activated.

 Time not synched for all protection relays.
 Previous recorded DRs are not supportive at our case, as date and time is wrong
 No events were recorded
 No expected root cause defined as the P.Ts are healthy without any problems during operation around eight
years.
 No preventive maintenance done by the manufacturer.
 No one can expect any mechanical impact took place for the P.Ts

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Recommendations

 A preventive maintenance should be done by the manufacturer inside the shelters to

confirm that all the switchgears are operated in a compatible way with the existing site
conditions (Dust & Humidity).
 Making sure that the shelters are completely sealed in order to avoid the operation
problems due to the existing dust inside the shelters.
 Protection relays setting must be revised.
 Voltage protection function must be activated
 Date and time must be synched at all protection relays.
 Safety stock of is important to avoid shut down for a long period.

Additional Recommendations

 Phase L2 decolored Copper connection

Risk:
Arc Flash Occurrence

Corrective action proposed:

 Preventive maintenance by the manu-
facturer.

 Install Thermal monitoring in MV

SWG

Risk:
High Temp. rise may cause the
following
 The insulators will break down.
 Short lifetime for the panels.
 Explosion may occur.
 leakage current, tracking and flashover on
insulators.
Corrective action proposed:

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  Install TH110 at cable connection, to monitor temp. through local HMI or to be connected through exiting mon-
itoring system

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Conclusion
 No expected root cause defined as the P.Ts are healthy without any problems during
operation for around eight years.
 No preventive maintenance done by the manufacturer of the switchgear during last
eight years.
 No one can expect any mechanical impact during last eight years.
 Under/Over voltage to be activated as alarm only and to have wave capturing form as
recording log.

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