canberra bc act 2600 - department of · pdf filethat all defences bases with abb safelink...

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Engineering Notice Gino Jacovelli Assistant Director – Estate Engineering Policy Environment and Engineering Branch Brindabella Park Offices BP26-2-B083 PO Box 7925 CANBERRA BC ACT 2600 : (02) 6266 8173 : [email protected] 26 Feb 2015 1 of 76 DEEP-ID/OUT/2015/AF19356533 FOR INFORMATION To ALL Defence Electrical Operating Authorities / Network Operators ABB SAFELINK HIGH VOLTAGE ( 11,000 volts ) ELECTRICAL SWITCHGEAR Safety Incident – 16 June 2014. Background 1. On Monday 16 June 2014, during the course of routine electrical high voltage operations, RAAF Darwin experienced a malfunction with one of its high voltage electrical switches. The switch in question was an ABB SafeLink Switch manufactured in 2004. 2. The malfunction occurred when the authorised operator, electrician, was standing directly in front of the switch switching it from the ON to the OFF position. The switch had overshot the OFF position causing the internal LIVE, 11,000 volt, electrical contacts to come close to the internal fixed EARTH contacts. This in effect created a direct 11,000 volt short circuit. Fortunately the electrical protection systems upstream within the RAAF Darwin Intake Switching Station operated immediately to disconnect the 11,000 volt electricity before the incident could cause further harm. 3. If the electrical protection systems had not operated within their designated time frames, this incident had the potential to create an explosion which could have caused fatal or serious injuries to the operator and anyone nearby. 4. Enquiries by the Electrical Operating Authority for RAAF Darwin with some Electricity Network Service Providers has identified that the problem with the 2004 manufactured switches are known within the industry and that similar incidents have occurred. 5. The Electrical Operating Authority for RAAF Darwin has enacted the following precautions for their jurisdiction, covering all Defence establishments within Darwin and Katherine, until the incident has been fully investigated and an agreed course of action developed by Defence in relation to this particular switch; a. ABB SafeLink switches are NOT to be operated when energised, the switchgear is to be de-energised. 6. The CMS Contractor at the time, Spotless, had notified both NT Worksafe and Comcare of the incident. 7. The Electrical Operating Authority for RAAF Darwin had also sought the advice and assistance of DEEP in relation to this incident.

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Page 1: CANBERRA BC ACT 2600 - Department of · PDF fileThat all Defences Bases with ABB SafeLink switchgear immediately obtain and put into operational practice, ( with the appropriate training,

Engineering Notice

Gino Jacovelli Assistant Director – Estate Engineering PolicyEnvironment and Engineering Branch Brindabella Park Offices BP26-2-B083 PO Box 7925 CANBERRA BC ACT 2600 : (02) 6266 8173 : [email protected]

26 Feb 2015 1 of 76

DEEP-ID/OUT/2015/AF19356533 FOR INFORMATION To ALL Defence Electrical Operating Authorities / Network Operators ABB SAFELINK HIGH VOLTAGE ( 11,000 volts ) ELECTRICAL SWITCHGEAR Safety Incident – 16 June 2014. Background 1. On Monday 16 June 2014, during the course of routine electrical high voltage operations, RAAF Darwin experienced a malfunction with one of its high voltage electrical switches. The switch in question was an ABB SafeLink Switch manufactured in 2004.

2. The malfunction occurred when the authorised operator, electrician, was standing directly in front of the switch switching it from the ON to the OFF position. The switch had overshot the OFF position causing the internal LIVE, 11,000 volt, electrical contacts to come close to the internal fixed EARTH contacts. This in effect created a direct 11,000 volt short circuit. Fortunately the electrical protection systems upstream within the RAAF Darwin Intake Switching Station operated immediately to disconnect the 11,000 volt electricity before the incident could cause further harm.

3. If the electrical protection systems had not operated within their designated time frames, this incident had the potential to create an explosion which could have caused fatal or serious injuries to the operator and anyone nearby.

4. Enquiries by the Electrical Operating Authority for RAAF Darwin with some Electricity Network Service Providers has identified that the problem with the 2004 manufactured switches are known within the industry and that similar incidents have occurred.

5. The Electrical Operating Authority for RAAF Darwin has enacted the following precautions for their jurisdiction, covering all Defence establishments within Darwin and Katherine, until the incident has been fully investigated and an agreed course of action developed by Defence in relation to this particular switch;

a. ABB SafeLink switches are NOT to be operated when energised, the switchgear is to be de-energised.

6. The CMS Contractor at the time, Spotless, had notified both NT Worksafe and Comcare of the incident.

7. The Electrical Operating Authority for RAAF Darwin had also sought the advice and assistance of DEEP in relation to this incident.

Page 2: CANBERRA BC ACT 2600 - Department of · PDF fileThat all Defences Bases with ABB SafeLink switchgear immediately obtain and put into operational practice, ( with the appropriate training,

Defence’s Exposure

8. Enquires through Defence’s Electrical Operating Authorities / Network Operators has identified some 47 ABB SafeLink high voltage switches in services. The locality of these units is detailed in Attachment A.

Consultation with Energy Networks Association ( ENA. )

9. Consultations with the ENA have established that the Australian electricity distributors are well aware of the problems with the operating mechanism with this particular high voltage switchgear. New South Wales, Queensland and South Australian electricity distributors have advised of their experiences with similar operational mechanism mal-functions.

10. The electricity distributor industry has been working in conjunction with the switchgear’s manufacturer, ABB, to identify the cause of the mal-functions and the repairs required. They have also developed an operating handle retro-fit that is attached to the switchgear when it is required to be operated. The Handle Arrester is attached by the operator to the unit’s operating handle. This Handle Arrester, in the event that the operating mechanism fails, restricts the electrical contacts from coming into contact with either earthed or live contacts.

11. The detail of these enquires and information provided by electricity distributors are contained in Attachments C to I.

What is the Hazard?

12. The ABB SafeLink is one of many types of switches used in Defence’s high voltage electricity networks. This switch is designed for an authorised person to safely switch high voltage on and off to equipment whilst they are standing directly in front of the switch.

13. In this particular case, a mal-function within the internal operating mechanism can allow the electrical contacts to come in close proximity or in contact with the Earth position. If the electrical contacts are ALIVE at the time, ie have 11,000 volts on them, this will create a short circuit generating an enormous quantity of energy to be released. If the electrical protection systems within the network either fail to interrupt this fault or are slow to react, the energy will not be limited sufficiently and the person standing in front of the switch will be subject to an electrical explosion exposing them to serious or fatal injury.

14. The technical details of the malfunction are set out in Attachment J – ABB Instruction SafeLink Handle Arrester Functional Description and Attachment I – ABB and Energex SafeLink Presentation.

15. ABB in conjunction with the electricity distributors have identified that the problem is predominately with the 2004 year model units. It is not solely restricted to this model as sporadic mal-functions have and do occurr across the range of models up to 2010.

What is the Industry doing to address the problem?

16. The electricity distributors in conjunction with ABB have instituted the following practices and procedures to manage the risk of ABB SafeLink switchgear malfunction.

17. Most electricity distributors have replaced the operating mechanism to their 2004 units.

18. Until the operating mechanism to 2004 units have been replaced, NO LIVE switching is carried out with these units.

26 Feb 2015 2 of 76

Page 3: CANBERRA BC ACT 2600 - Department of · PDF fileThat all Defences Bases with ABB SafeLink switchgear immediately obtain and put into operational practice, ( with the appropriate training,

19. All electricity distributors have introduced the ABB Handle Arrester to be used at all times any switching or earthing of an ABB SafeLink is required. These are to be used on all models even if their operating mechanisms have been replaced. This Handle Arrestor will in the event of an operating mechanism malfunction restrict the live contacts from coming into contact with earth and exposing the operator to an electrical fault.

20. Should an operating mechanism malfunction be identified, the unit has its operating mechanism replaced. NO LIVE switching is carried with the unit until its operating mechanism has been replaced.

21. The Attachments D to H provide the details on the procedures and operating instructions implemented by the electricity distributors Ausgrid, Ergon, Endeavour Energy, SA Power and Energex.

RECOMMENDATIONS

22. The operation and maintenance of the Defence high voltage networks is managed within DSRG’s DSO Division. In this regard it is recommended that DSO undertake the following actions;

Recommendation 1

23. Ensure that all the Defence Electrical Operating Authorities and Electrical Operators for high Voltage networks are made aware of the issues associated with ABB SafeLink Switchgear and are provided with this report.

Recommendation 2

24. That all Defence sites with high voltage switchgear check and confirm if they have any ABB SafeLink switchgear in service.

Recommendation 3

25. That NO LIVE Operation of any 2004 model ABB SafeLink switchgear, which has not had it’s operating mechanism replaced, be carried out.

a. This will impact RAAF Darwin and Lavarack Barracks.

Recommendation 4

26. That the operating mechanism for all 2004 model ABB SafeLink Switchgear be replaced ASAP.

a. This will impact RAAF Darwin – 1 unit and Lavarack Barracks – 3 units.

b. Estimated cost $16,000

Recommendation 5

27. That all Defences Bases with ABB SafeLink switchgear immediately obtain and put into operational practice, ( with the appropriate training, work practices, polices and procedures ) Handle Arresters for all operations of switching and earthing ABB SafeLink switchgear.

a. Attachment A lists those Defence Bases with ABB SafeLink units and the number of units on site.

b. Attachment K – sets out ABB’s Instruction for SafeLink Handle Arrester Operating Procedure, and

c. Attachments E, F and G contain instructions provided for the operation of Handle Arresters as implemented by ERGON, Endeavour Energy and Energex.

26 Feb 2015 3 of 76

Page 4: CANBERRA BC ACT 2600 - Department of · PDF fileThat all Defences Bases with ABB SafeLink switchgear immediately obtain and put into operational practice, ( with the appropriate training,

d. Estimated cost for the supply of Handle Arresters for all ABB SafeLink switchgear $31,000.

Recommendation 6

28. That all Defence Bases with SafeLink high voltage switchgear develop and implement polices, procedures and work practices and train their authorised electrical operators as to actions to be taken in the event of any mal-operation of a unit.

a. Attachment L – ABB RMU SafeLink Indication Using Handle Arrester provides indication of any mal-operation when the Handle Arrester is used.

Industry Contacts

29. Manufacture’s Contact, ABB - The contact for the supply and advice in relation to the replacement operating mechanisms and Handle Arresters is;

ABB New Zealand

Mr Rex DeBruyn – Marketing and Export Manager

ph - +642199 4793

email – [email protected]

30. Australian Electricity Distributor - Energex is the best placed distributor to contact. Energex has undertaken extensive investigations to identify the cause of the mal-functions and has worked closely with ABB to develop the repairs required and the use of the Handle Arresters. The Energex contact is;

Mr Gary Towler – Principal Engineer Reactive Maintenance

26 Reddacliff Street, Newstead, QLD, 4006

ph – 07 3664 4071

email [email protected]

Gino Jacovelli Assistant Director – Estate Engineering Policy Electrical Engineer Environment and Engineering Branch 26 February 2015. Attachments A. Defence ABB SafeLink high voltage switchgear Register. B. Cost Estimates for the Supply of ABB SafeLink Switchgear Mechanisms and Handle Arresters. C ENA, Energy Networks Association, Enquires. D. AusGrid Advice E. Ergon Advice. F. Endeavour Energy Advice. G. SA Power Advice. H. Energex Advice I. ABB and Energex SafeLink Presentation. J. ABB Instruction – SafeLink Handle Arrester Functional Description. K. ABB Instruction – SafeLink Handle Arrester Operating Procedure. L. ABB Instruction – SafeLink State Indicator Using the Handle Arrester.

26 Feb 2015 4 of 76

Page 5: CANBERRA BC ACT 2600 - Department of · PDF fileThat all Defences Bases with ABB SafeLink switchgear immediately obtain and put into operational practice, ( with the appropriate training,

Attachment A – Defence ABB SafeLink Switchgear Register.

1. DEEP had issued a task to the DSO Regions on the 9 July 2014, seeking the Regional Electrical Operating Authorities to advise if they have any ABB SafeLink switchgear in service.

2. Table 1, below, provides a summary of the location of ABB SafeLink switchgear on Defence establishments.

3. Table 2, below, provides a listing of the responses received from DSO Regions in response to DEEP’s enquiry.

Table 1 – Location of ABB SafeLink Switchgear.

Location of AAB SafeLink Switchgear No. on site Year of Manufacture & No. in service

Vic – Anglesea Barracks 1 2006 - 1 Darwin RAAF 14 2003 - 3

2004 - 1 2006 - 10

Robertson Barracks - Darwin 1 2008 - 1 Liverpool - NSW 2 2001 - 1

2010 - 1

Williamtown RAAF 2 2003 -1 2005 -1

Glenbrook RAAF in NSW Blue Mountains 1 2011 - 1 Enoggera Barracks - North West Brisbane 1 2005 - 1 Lavarack Barracks - Townsville 9 2002 - 2

2003 - 1 2004 - 3 2008 - 2 2009 - 1

Forrest Hill RAAF- Wagga Wagga 1 2009 - 1 Edinburgh - SA 2 2002 - 1

2003 - 1

Woomera - SA 13 2002 - 12 2008 - 1

Total No. in service 47

26 Feb 2015 5 of 76

Page 6: CANBERRA BC ACT 2600 - Department of · PDF fileThat all Defences Bases with ABB SafeLink switchgear immediately obtain and put into operational practice, ( with the appropriate training,

Annexure A – Defence ABB SafeLink Switchgear Register.

Table 2 - ABB SafeLink Switchgear advised by Defence Regions as at 1 September 2014.

No. Region Base Substation Switch station

No.

ABB SafeLink Serial No.

ABB SafeLink Date of

Manufacture

ABB SafeLink Configuration

1 Vic/Tas Anglesea Barracks 1 1YJN109352 2006 CFC

2 Central/West - NT/K

RAAF Darwin 3 1YJN107850

2006 CFC

3 Central/West - NT/K

RAAF Darwin 5 01338 2003 CFC

4 Central/West - NT/K

RAAF Darwin 8 1YJN104172

2004 CFC

5 Central/West - NT/K

RAAF Darwin 9 1YJN107845

2006 CFC

6 Central/West - NT/K

RAAF Darwin 10 01333 2003 CFC

7 Central/West - NT/K

RAAF Darwin 11 01340 2003 CFC

8 Central/West - NT/K

RAAF Darwin 13 1YJN07849

2006 CFC

9 Central/West - NT/K

RAAF Darwin 14 1YJN107844

2006 CFC

10 Central/West - NT/K

RAAF Darwin 17 1YJN107842

2006 CFC

11 Central/West - NT/K

RAAF Darwin 18 1YJN107846

2006 CFC

12 Central/West - NT/K

RAAF Darwin 19 1YJN107843

2006 CFC

13 Central/West - NT/K

RAAF Darwin 21 1YJN107848

2006 CFC

14 Central/West - NT/K

RAAF Darwin 22 1YJN107852

2006 CFC

15 Central/West - NT/K

RAAF Darwin 23 1YJN07851

2006 CFC

16 Central/West - NT/K

Robertson Barracks 70 1YJN35225407 2008 CFC

17 Liverpool Military Area

DNSDC 1343 1YJN1490201 2010 CFC

18 Liverpool Military Area

DNSDC 1396 1YJN17184718 2001 CFC

19 NNSW RAAF Williamtown 19 01854 2003 CFCC

20 NNSW RAAF Williamtown 23 1YJN106115 2005 CFC

21 NNSW RAAF Glenbrook No1 0885/092

1YJN024054219 2011 CFC

22 QLD Enoggera 20 1YJN105375 2005 CFC

23 QLD Lavarack 5 1YJN35354201 2009 CFC

24 QLD Lavarack 50 1YJN103967 2004 CFC

25 QLD Lavarack 53 1YJN114711 2008 CFC

26 QLD Lavarack 3 1YJN114710 2008 CFC

27 QLD Lavarack 49 01294 2003 CFC

28 QLD Lavarack 15 01057 2002 CFCC

29 QLD Lavarack 45 01056 2002 CFCC

30 QLD Lavarack 13 1YJN103397 2004 CFC

31 QLD Lavarack 12 1YJN103392 2004 CFC

32 NSW RAAF Forrest Hill SS14 1YJN38761512 2009 CFC

33 Central/West - SA

RAAF / DSTO RAAF 35 01059 2002 CFCF

34 Central/West - SA

RAAF / DSTO RAAF 36 01546 2003 CFC

26 Feb 2015 6 of 76

Page 7: CANBERRA BC ACT 2600 - Department of · PDF fileThat all Defences Bases with ABB SafeLink switchgear immediately obtain and put into operational practice, ( with the appropriate training,

Annexure A – Defence ABB SafeLink Switchgear Register.

26 Feb 2015 7 of 76

No. Region Base Substation Switch station

No.

ABB SafeLink Serial No.

ABB SafeLink Date of

Manufacture

ABB SafeLink Configuration

35 Central/West - SA

Woomera TC202 00591 2002 CFC

36 Central/West - SA

Woomera TC203 00590 2002 CFC

37 Central/West - SA

Woomera TC205 00586 2002 CFC

38 Central/West - SA

Woomera TC207 00587 2002 CFC

39 Central/West - SA

Woomera TC209 00585 2002 CFC

40 Central/West - SA

Woomera TC210 00588 2002 CFC

41 Central/West - SA

Woomera TC211 00589 2002 CFC

42 Central/West - SA

Woomera TC212 00583 2002 CFC

43 Central/West - SA

Woomera TC213 00593 2002 CFC

44 Central/West - SA

Woomera TC224 00594 2002 CFC

45 Central/West - SA

Woomera TC502 00584 2002 CFC

46 Central/West - SA

Woomera C201 00595 2002 CFC

47 Central/West - SA

Woomera Radar2 1YJN114391 2008 CFC

Page 8: CANBERRA BC ACT 2600 - Department of · PDF fileThat all Defences Bases with ABB SafeLink switchgear immediately obtain and put into operational practice, ( with the appropriate training,

Attachment B –Cost Estimates for the Supply of ABB SafeLink Switchgear Mechanisms and Handle Arresters.

Year of Manufacture

Cost Est Recommendation

3

Cost Est Recommendation

4

TOTAL Estimated Cost per

Site &

Location of ABB SafeLink Switchgear No. on site

No. in service Vic – Anglesea Barracks 1 2006 - 1 1 $ 650 $ 650

2003 - 3 3 $ 1,950 $ 12,980 2004 - 1 1 $ 3,880 $ 650

Darwin RAAF 14

2006 - 10 10 $ 6,500 Robertson Barracks - Darwin 1 2008 - 1 1 $ 650 $ 650

2001 - 1 1 $ 650 $ 1,300 Liverpool - NSW 2 2010 - 1 1 $ 650 2003 -1 1 $ 650 $ 1,300 Williamtown RAAF 2 2005 -1 1 $ 650

Glenbrook RAAF in NSW Blue Mountains 1 2011 - 1 1 $ 650 $ 650 Enoggera Barracks - North West Brisbane 1 2005 - 1 1 $ 650 $ 650

2002 - 2 2 $ 1,300 $ 17,490 2003 - 1 1 $ 650 2004 - 3 3 $ 11,640 $ 1,950 2008 - 2 2 $ 1,300

Lavarack Barracks - Townsville 9

2009 - 1 1 $ 650 Forrest Hill RAAF- Wagga Wagga 1 2009 - 1 1 $ 650 $ 650

2002 - 1 1 $ 650 $ 1,300 Edinburgh - SA 2 2003 - 1 1 $ 650 2002 - 12 12 $ 7,800 $ 8,450 Woomera - SA 13 2008 - 1 1 $ 650

$ - Total No. in service 47

$ 15,520 $ 30,550 $ 46,070 $ 16,000 $ 31,000

26 Feb 2015 8 of 76

Page 9: CANBERRA BC ACT 2600 - Department of · PDF fileThat all Defences Bases with ABB SafeLink switchgear immediately obtain and put into operational practice, ( with the appropriate training,

Attachment B –Cost Estimates for the Supply of ABB SafeLink Switchgear Mechanisms and Handle Arresters.

26 Feb 2015 9 of 76

Price ex NZ

Est Price Del Aust

ABB Budget prices

Handle Arrester - main and earth $ 450.00 $ 650.00

Ring Switch Mechanism $ 355.00 $ 555.00

Switch fuses mechanism $ 630.00 $ 830.00

Enquires for purchase of the above should be directed to

ABB New Zealand

Mr Rex DeBruyn – Marketing and Export Manager

ph - +642199 4793

email – [email protected]

Recommendation 3 costing – based upon 3 way unit comprising 2 x ring main switches and a fuse switch. Costing per unit estimated at Materials 2 x $555 + $830 = $1,940 Labour = $1,940 TOTAL =$3,880 Recommendation 4 costing – based upon a handle arrester for each ABB SafeLink units on site. Ie. $650 x number of units

Page 10: CANBERRA BC ACT 2600 - Department of · PDF fileThat all Defences Bases with ABB SafeLink switchgear immediately obtain and put into operational practice, ( with the appropriate training,

Attachment C – ENA, Energy Networks Association - Enquires.

1. Enquires were made to the ENA on the 18 June 2014 seeking their assistance and advice in relation to any experiences their membership may have had with ABB SafeLink switchgear.

2. Responses were received from AusGrid, Ergon, Endeavour Energy, SA Power and Energex. The responses are surmised below.

AusGrid

3. AusGrid advise that the industry is aware of the issue and that they have experienced 1 failure. Attachment C has their full response.

Ergon

4. Ergon advise of a significant number of malfunctions, the majority with 2003 and 2004 year of manufacture models but also in later year models. Ergon has replaced the operating mechanism in 2003 and 2004 units. They have also replaced the operating mechanism in later model units as and when these have malfunctioned.

5. ABB has progressively introduced a number of modifications and has also produced an OVER TRAVEL ARRESTOR to prevent the isolator / earth switch contacts from over travelling during a malfunction. This OVER TRAVEL ARRESTOR has been introduced in to its operations.

6. A procedure / instruction in relation to the operation of ABB SafeLink units is provided This instruction is contained in Attachment D and can also be accessed via Objective document AF18520355.

7. Attachment D has their full response.

Endeavour Energy

8. Endeavour Energy advise that for their 2004 models, some 400 in service, ABB have provided the replacement mechanisms and provided the training to their staff in the replacement of the operating mechanism. The operating mechanisms in all 2004 models have been replaced.

9. ABB have also provided a handle arrester that is to be used on all model ABB SafeLink switchgear. This handle arrester will prevent over travel in the event of the operating mechanism malfunctioning. All Endeavour Energy electrical operating staff have been trained in the use of the handle arrester.

10. Endeavour Energy’s instruction in the operation of the handle arrester is contained in Attachment E. This instruction may also be accessed via Objective document AF18350631.

11. Contact person at Endeavour Energy is Mr Raymond Danam, Act Substation Manager – 02 9853 4129.

12. Attachment E has their full response

26 Feb 2015 10 of 76

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26 Feb 2015 11 of 76

SA Power

13. SA Power has some 195 ABB SafeLink units in service, 12 of these are the 2004 model. At present no repairs to these units have been carried out.

14. At present SA Power has an instruction that no live switching is be undertaken with it 2004 units. SA Power’s instruction in relation to these units is set out in Attachment F. This instruction may also be accessed via Objective document AF18520374.

Energex

15. Energex has over some 8,500 ABB SafeLink units in service, with approximately 1,000 been the 2004 model.

16. Of the 2004 model at least 100 units have failed. The operating mechanism of all the 2004 model units have been replaced. It is also seeking to replace the mechanism to all 2003 units.

17. Energex has had a lead role in investigating and identifying the cause of the failures of the ABB SafeLink units. It has also worked closely with ABB’s New Zealand factory to identify the cause and to develop solutions.

18. Energex sporadically continues to experience failure of the operating mechanism across its ABB SafeLink units. Where and when a unit is identified, that unit is tagged to not be operated LIVE and scheduled to have its operating mechanism replaced.

19. All ABB SafeLink units are to be only operated by an externally mounted over travel device. This is the same device as per Ergon’s over travel arrestor.

20. Energex is unable to provide any details as to any of the arrangements and or agreements it has come to with ABB in address the problems with its ABB SafeLink units as these are commercial in confidence.

21. Energex’s Safety Alert in relation to ABB SafeLink switchgear and its operation is set out in Attachment G. This alert may also be accessed via Objective document AF18520401.

22. Energex’s principal contact person in relation to this matter is

Mr Gary Towler

Principal Engineer – Reactive Maintenace

ph 07 3664 4071

23. An ABB Powerpoint presentation in relation to ABB’s and Energex’s joint investigation is included at Attachment H. This presentation may also be accessed via Objective document AF18350686.

Page 12: CANBERRA BC ACT 2600 - Department of · PDF fileThat all Defences Bases with ABB SafeLink switchgear immediately obtain and put into operational practice, ( with the appropriate training,

Attachment D – AusGrid Advice.

  From: Darko Grcev [mailto:[email protected]] Sent: Thursday, 26 June 2014 10:32 AM To: Stuart Johnston Cc: [email protected]; Terry Lampard; David Wilkinson Subject: Re: Fw: Department of Defence - ABB SafeLink HV Switchgear incident - 16 June 2014 [SEC=UNCLASSIFIED] Hi Stuart, the malfunction experienced by the Department of Defence involving ABB Safelink RMUs manufactured up to 2004 is a well known issue across the industry. ABB have confirmed that there are several modes of failure as shown below.

Energex, Ergon, Vector NZ and other distributors have experienced issues with these units. Ausgrid has had one failure of a similar nature and we are going through the investigation at present (cause undetermined as yet). We have received a report from ABB on the Ausgrid failure which I am hesitant to share until the investigation is complete (no injuries to staff or public - protection cleared the fault). According to ABB one of the main reasons for failure of the 2004 manufactured units (switching on --> off --> earth) has been the latch failing to stop the moving contacts in the off position so the contacts had the potential to over travel to the earth position. ABB has indicated that this is due to the grease used in the 2004 manufactured units which was impeding the operation/speed of the latch(s). There are reports of over travel occuring the other way as well (unit at Ergon made in 2010) due to the RMU mechanism being infested with insect nests (ants and cock roaches) which resulted in considerable debris and formic acid build up that inhibited the operation of the mechanism and created an corrosive environment. I am aware that Gary Towler has prepared a presentation on the failures experienced by Energex which was presented at a industry meeting in 2010. Gary may wish to share the details. Regards Darko Grcev Manager - Transmission & Distribution Substation Engineering Primary Systems Branch Ausgrid Ph 02 9394 6066 Mob 0409 392 932  

   

26 Feb 2015 12 of 76

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Attachment D – AusGrid Advice.

26 Feb 2015 13 of 76

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Attachment D – AusGrid Advice.

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Page 15: CANBERRA BC ACT 2600 - Department of · PDF fileThat all Defences Bases with ABB SafeLink switchgear immediately obtain and put into operational practice, ( with the appropriate training,

Attachment E – Ergon Advice.

Gino, Please find the response and attachments on this issue from Ergon Energy, Regards, Stuart  

Dr Stuart Johnston Program Manager, Energy & Gas Infrastructure Energy Networks Association  Level 1, 110 Giles Street Kingston ACT 2604 E:   [email protected] , T:   61 2 6272 1513, M:  0429 326 624  From: JENSEN Christian (NQ) [mailto:[email protected]] Sent: Thursday, 26 June 2014 3:02 PM To: Stuart Johnston Cc: LEWIS Ken (NQ) Subject: FW: Department of Defence - ABB SafeLink HV Switchgear incident - 16 June 2014 [SEC=UNCLASSIFIED] Hi Stuart,  Regarding the below request from the Department of Defence, I have provided some documents (attached) which details to some degree how Ergon Energy has responded to similar failures within our own network.   I am probably the best placed person within Ergon Energy should DoD wish to have any further discussions, however will be on leave from 27 June returning 08 July.  They are more than welcome to contact me on the details below on my return. If they wish for information sooner, they can contact Ken Lewis (who I have CC’d into this email).  Regards,  Christian  

Christian Jensen 

Senior Engineer Investigations  Ergon Energy 

420 Flinders Street, Townsville QLD 4810 PO Box 1090, Townsville QLD 4810 P 07 4432 8977  M 0457 537 010  F 07 4432 8030   E [email protected]  

ergon.com.au 

 

             

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Attachment E – Ergon Advice.

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Attachment E – Ergon Advice.

26 Feb 2015 17 of 76

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Attachment E – Ergon Advice.

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Attachment E – Ergon Advice.

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Attachment E – Ergon Advice.

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Attachment F – Endeavour Energy Instruction.

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Attachment F – Endeavour Energy Instruction.

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Attachment F – Endeavour Energy Instruction.

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Attachment F – Endeavour Energy Instruction.

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Attachment F – Endeavour Energy Instruction.

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Attachment F – Endeavour Energy Instruction.

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Attachment F – Endeavour Energy Instruction.

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Attachment F – Endeavour Energy Instruction.

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Attachment F – Endeavour Energy Instruction.

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Attachment F – Endeavour Energy Instruction.

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Attachment F – Endeavour Energy Instruction.

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Attachment F – Endeavour Energy Instruction.

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Attachment F – Endeavour Energy Instruction.

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Attachment G – SA Power Instruction.

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Attachment H – Energex Advice.

Gino, Please find a further response from Energex on your issue with SafeLink. Regards, Stuart  Dr Stuart Johnston Program Manager, Energy & Gas Infrastructure  Energy Networks Association  Level 1, 110 Giles Street Kingston ACT 2604 E:   [email protected] , T:   61 2 6272 1513, M:  0429 326 624    From: TOWLER Gary (Energex) [mailto:[email protected]] Sent: Monday, 7 July 2014 8:55 AM To: Stuart Johnston Subject: ABB SafeLink maloperation Hi Stuart, Sorry to hear of your recent SafeLink failure, however, it is good that nobody was hurt in the incident. This is not a new issue and I’m surprised that you have not been informed by ABB or heard otherwise about this problem. Our earliest example of a Safelink mechanism switch overtravel failure of the type you describe was in November 2009. After extensive investigations, Energex’s view is that the reason for the maloperation was the combination of three factors:

1. A (redundant) cam lobe that held a latch in the incorrect position;

2. Heavy grease that impeded the latch return movement to the correct position;

3. Weak latch springs acting on the latch.

  Due to mechanism symmetry, it was also observed that the fault could happen in either direction. i.e. the overtravel could occur when opening the earth switch, hence inadvertently (momentarily) making a cable live that may be subject to personnel access via a permit to work. Initially the failures were predominantly from the 2004 batch and the reason ABB offered was a heavy grade grease used through 2004. Despite changes in the grease in late 2004, the other two factors relating to the failure remained and did indeed eventually result in failures of later models. In 2010 ABB modified the mechanism to remove all three failure modes discussed above. However, by that time Energex had some 8,500 SafeLink RMUs on the network. In some cases the consequence of the switch failure was an actual tank rupture due to the internal arcing fault created by the overtravel. To manage this Energex implemented a series of operating restrictions as the defect progressed through the YOM models to later units. Over a period of approximately three years Energex experienced approximately 100 mechanism malfunctions from the YOM 2004 batch alone, mostly during de-energised operation due to the operating restriction. The solution was to retrofit all YOM2004 units (approximately 1000) with the later 2010 design mechanism and for all other units, implement an externally fitted overtravel arrestor that was developed in conjunction with ABB. This device is temporarily attached at the time of switching and effectively prevents the switch from over travelling if the latch should maloperate. Presently, ALL SafeLink RMUs are operated using this overtravel arrestor device.

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Attachment H – Energex Advice.

Throughout the entire investigation, all other Australian and NZ utilities were involved and I communicated with them by means of:

Phone conversations with Engineers investigating similar failures;

Sharing of failure investigation reports;

Presentations at regular (6 monthly) Industry Working Group conferences held countrywide;

Visits (to other utilities and to ABB) with other utility Engineers to assist in investigations.

    As I’m sure you will understand I cannot discuss any of the commercial agreements with ABB, but If you require any more engineering information please don’t hesitate to drop me an email or call.       Regards, Gary Towler Principal Engineer Reactive Maintenance Energex Limited

Phone: Mob: 0400 700 739, Desk: 07 3664 4071, Switchboard: 07 3664 4000, Fax: 07 3664 9836 Address: Level 5, ENERGEX Corporate Office, 26 Reddacliff Street, Newstead, Qld 4006. www.energex.com.au Please consider the environment before you print this e-mail.

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Attachment H – Energex Advice.

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Attachment H – ABB & Energex SafeLink Presentation AF18350686

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Attachment I – ABB & Energex SafeLink Presentation AF18350686

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Attachment J – ABB Instruction SafeLink Handle Arrestor Functional Description

AF19301997.

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Attachment J – ABB Instruction SafeLink Handle Arrestor Functional Description

AF19301997.

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Attachment K – ABB Instruction SafeLink Handle Arrestor Operating Procedure

AF19301999.

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Attachment K – ABB Instruction SafeLink Handle Arrestor Operating Procedure

AF19301999.

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Attachment K – ABB Instruction SafeLink Handle Arrestor Operating Procedure

AF19301999.

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Attachment K – ABB Instruction SafeLink Handle Arrestor Operating Procedure

AF19301999.

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Attachment K – ABB Instruction SafeLink Handle Arrestor Operating Procedure

AF19301999.

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Attachment K – ABB Instruction SafeLink Handle Arrestor Operating Procedure

AF19301999.

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Attachment K – ABB Instruction SafeLink Handle Arrestor Operating Procedure

AF19301999.

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Attachment K – ABB Instruction SafeLink Handle Arrestor Operating Procedure

AF19301999.

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Attachment K – ABB Instruction SafeLink Handle Arrestor Operating Procedure

AF19301999.

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Attachment K – ABB Instruction SafeLink Handle Arrestor Operating Procedure

AF19301999.

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Attachment K – ABB Instruction SafeLink Handle Arrestor Operating Procedure

AF19301999.

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Attachment K – ABB Instruction SafeLink Handle Arrestor Operating Procedure

AF19301999.

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Attachment L – ABB Instruction SafeLink – State Indicator Using the Handle Arrestor

AF19302001.

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