ISSUED MASTER SPECIFICATION

Originated by Larry Faught on 29/11/2001

SPECIFICATION DETAILS Status: Issued

Discipline: Design Criteria

Equipment: Design Codes
Title: Design Construction And Maintenance Of Electrical Substations And Mcc
Rooms
Description: Design Codes Mines

MASTER SPECIFICATION NUMBER

Specification No: ADC004
Specification Rev No: 02

- ADC004-02~1.doc
 ANGLO PLATINUM MANAGEMENT SERVICES (PROPRIETARY) LIMITED
ENGINEERING TECHNOLOGY DIVISION

DESIGN CODE - ADC-004

for

DESIGN, CONSTRUCTION AND MAINTENANCE OF ELECTRICAL

SUBSTATIONS AND MCC ROOMS

Rev. Date Revisions Originator

0 18.02.99 Issued in “Anglo Platinum” format DLE
1 12.03.99 Minor revisions as indicated DLE
2 22/11/2001 Clauses 1.1.13 and 1.1.16 revised, DLE
Claus 1.7 added

Page 1 of 13
Spec. No. ADC004 Rev. 02
 CONTENTS

SECTION TITLE

1.0 DESIGN AND CONSTRUCTION

1.1 Substation Layout and Construction Details

1.2 Switchgear Protection
1.3 Battery Tripping Units
1.4 Transformers
1.5 Fire Protection
1.6 Design Deviations
1.7 Remotely Interogatable Metering

2.0 MAINTENANCE

2.1 Fire Protection

2.2 Battery Tripping Units
2.3 Transformer Maintenance
2.4 Switchgear
2.5 Record Books
2.6 Independent Audits

3.0 REFERENCE DRAWINGS

- STD 005 19006 12

- STD 005 19006 22
- STD 005 19002 12
- STD 005 19002 22
- STD 005 09018 11
- STD 005 09020 11
- STD 005 29004 11

4.0 REFERENCE SPECIFICATIONS:

- AEL-027 - Battery Tripping Units.

- AEL-029 - Substation Fire Protection.

This code sets out the design, construction and maintenance requirements for electrical substations.
Equipment details are covered in existing Electrical (AEL) Specifications.

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Spec. No. ADC004 Rev. 02
1.0 DESIGN AND CONSTRUCTION

1.1 Substation Layout and Construction Details

1.1.1 Large centralised electrical equipment areas shall be avoided in the design of
new electrical installations. Instead, careful consideration shall be given to
ensuring that, as far as possible, equipment is geographically distributed into
load centres supplied from the main substation. In particular, every effort shall
be made to minimise multiple transformer installations and avoid centralised
LV switchgear, each of which poses a serious fire hazard.

1.1.2 Where, for any reason, it is impossible in a main substation to avoid siting
multiple transformers and their associated HV and LV (550V) switchgear
within a limited area, it is essential that segregation be maintained between
these components within that area. This demands separation of the HV and LV
(550V) switchgear in separate rooms, divided by an effective firewall, with all
transformers being located in a separate, external transformer bay section.
Where possible, LV and HV cables shall not be led through the intervening
firewall. (Drawing No. STD 005 09018 11).

1.1.3 Each distributed load centre shall be equipped with its complement of
transformer(s) fed from local HV switchgear, which latter may take the form of
one or more ring main switches or, alternatively, conventional SF6 or vacuum
circuit breaker panels. Where the distance between a transformer (or motor,
etc.) and an isolatable switch supplying it does not exceed 200m by the shortest
practicable route, local HV switchgear is not mandatory.

The load centre HV and LV switchgear shall be installed in separate rooms

divided by an effective firewall, except that where a load centre contains one
transformer only (with no prospect of further expansion) the HV and LV
switchgear may, at the discretion of the Anglo Platinum Engineer, be
positioned in one room. All switchgear must then be oil-free (Drawing
No. STD 005 19020 11).

1.1.4 Transformers must be located on correctly engineered bases within transformer

bays, each bay being surrounded on three sides by a blast wall of adequate
height. It is vital to ensure that a clear space of at least two meters exists
between the wall of the substation and the back wall of the transformer bays,
and that substation windows, ventilation openings and pressurising fans are not
located over the transformer bays.

Notwithstanding the above, load centre lighting transformers up to the

maximum permissible 150 kVA may, at the discretion of the Anglo Platinum
Engineer, be accommodated on a plain concrete pad with surrounding bund
wall to contain oil spillage in the event of the tank rupturing. This concession

Page 3 of 13
Spec. No. ADC004 Rev. 02
 shall apply only if the transformer is located such that there is no possibility of a
transformer fire spreading to adjacent plant or equipment.
1.1.5 Transformer bays shall be fitted with oil disposal facilities according to prevailing
Anglo Platinum Group standards as depicted in Drawing No.
STD 005 29004 11. In order to minimise external heating of the transformers,
the transformer bays may, at the discretion of the Anglo Platinum Engineer, be
fitted with detachable roofs constructed of non-flammable materials.

1.1.6 Parallel runs of multiple cables within substations must be avoided in order to
minimise fire risk. Instead, cables shall be led directly out of the substation, as
depicted in Drawing No. STD 005 09018 11, and marshalled onto racks
outside the substation. Cable ducts shall be avoided wherever possible in
favour of overhead racks.

In main consumer substations it is a requirement that all incoming and outgoing

feeder cables are each totally segregated from other cables, by means of brick
or concrete partitioning, across the respective cable trenches.

1.1.7 Where cables pass into and out of HV switchgear and MCC rooms via external
walls or internal firewalls, it is essential that the wall apertures be effectively
sealed with a suitable fire retarding compound after the cables have been led.
Alternatively, a weak concrete mixture with a high sand/cement ratio (typically
9:1) may be used.

1.1.8 Oil immersed neutral earthing compensators and resistors are particularly prone
to catastrophic failure in the event of an earth fault occurring on the system for
longer than approximately 15 seconds. It is essential that such devices are
surrounded by effective blast walls and mounted on soak pits, generally as for
transformer bays.

1.1.9 Underground substation design shall comply with Drawing

Nos. STD 005 19006 12/22 or STD 005 19002 12/22, as applicable. In
underground substations, oil-filled transformers and switchgear must be
separated by a brick wall. Bund walls shall be provided to contain burning oil
in the event of a transformer or minisub tank rupturing. In order to minimise
flame spread, the bund walls shall enclose a volume adequate to catch and
contain the total oil content of the unit, but covering a minimum surface area.

1.1.10 Generally it is not permissible to retro-fill cable ducts with sand as a precaution
against spread of fire unless the cable has been sized so as to allow for the low
thermal conductivity of dry sand.

Cables within the substation or MCC room shall be treated with an approved
flame-retardant coating (Intumastic 285 or similar) applied over a 2m length in
every 10m, and for a 2m length at every change of direction. In addition, cables
shall be coated over a length of at least 0,75m on each side of every entry point
into the substation, and on each side of any firewall or other barrier. Cables

Page 4 of 13
Spec. No. ADC004 Rev. 02
 less than 3m long shall be coated over their entire length. In particular the first
2m of every cable leaving a switchgear panel or MCC shall be coated.
1.1.11 Substation roofs shall be constructed of steel (e.g. IBR sheeting), pitched, and
fitted with ample fixed ridge ventilators in order to rapidly release smoke and
fumes in the event of an internal fire. The roof shall be internally clad with
industrial grade 'Sisalation' or equivalent thermal insulation, suitably supported
in position. Adequate door-mounted or other louvers shall be installed to
ensure a minimum air-flow of 5 air changes per hour.

False ceilings contain smoke and corrosive fumes within the substation, and
may be installed only where environmental conditions so demand. These
ceilings must be constructed of non-flammable materials. (See Section 1.5.5).

1.1.12 Where adequate natural ventilation is not possible, filtered pressurising fans shall
be fitted in the external walls of the substation (not adjacent to transformer
bays). Design capacity shall be at least 5 air changes per hour. The fans shall
be switched off automatically by the fire detection system in the event of a fire
(See Section 1.5).

1.1.13 A typical design for a main surface sub-station is depicted in Drawing

No. STD 005 09018 11. Note that the lowest point of the substation must be
above surrounding ground level to obviate the possibility of flooding.

Substations, including buildings referred to as Switchgear rooms or MCC

rooms, shall be designed with the following minimum clearances between the
respective vertical faces of the switchgear and the building structures or other
switchgear.

It is stressed that the clearances listed below are unobstructed. This

means, amongst other things, that it shall be clear of any other electrical
2 panels and any curbing or other structural members such as columns,
bracing, purlins, sheeting, etc.

- Behind HT Switchgear 1 200mm

- In front of HT Switchgear Circuit breaker draw out plus 1 000mm
- Behind LT Switchgear 750mm
- In front of LT Switchgear 1 200mm
- Behind Motor Control Centres 750mm
- In front of Motor Control Centres 1 800mm
- Above all switchgear 100mm to the underside of support
beams and 500mm to roof
structure/ceiling
- On the sides of all switchgear 1 individual panel width plus 800mm

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Spec. No. ADC004 Rev. 02
 1.1.14 HV switchgear within a substation shall be divided into zones, each zone
consisting of not more than 10 panels. Each zone shall be separated from the
next by means of a firewall fitted with a steel equipment door which is kept
closed except during periods of maintenance; this door shall not be lockable.
Any cable duct passing through the firewall shall have a fireproof barrier fitted
in the plane of the firewall. Zones should be designed so as to minimise losses
in overall production in the event of a total loss of any one zone.

1.1.15 As far as practicable, MCC's should be located singly in close proximity to the
motors served. Grouping of MCC's is strongly discouraged but, where this is
unavoidable, cable ducts and any cable basement shall be equipped with fire
protection facilities in accordance with Section 1.5.

1.1.16 Multi-storey electrical areas (comprising, typically, transformers, cable

basements, MCC's and control panels on different floors) pose an unacceptable
2 fire risk and are not permitted, except with the express written permission of
the Anglo Platinum Consulting Electrical Engineer.

1.1.17 All doors in firewalls shall comply with the requirements of SABS 0139 in
respect of Class B fire doors.

1.1.18 Every substation room and MCC room:

1.1.18.1 shall be fitted with at least two doors leading directly to the
exterior. Only one door shall be lockable from the outside, while
the other shall be fitted with a push-bar opening device such that it
can be readily opened from inside.

1.1.18.2 shall be adequately illuminated by means of fluorescent lighting

controlled by either a weatherproof switch on the external wall of
the substation or by means of a limit switch on the access door.
Lighting levels shall be at least 200 lux within the room area and
not less than 160 lux behind the panels. Vertical illumination
behind the panels shall not be less than 200 lux.

1.1.18.3 shall be provided with the following notices and signs:

i) Prohibiting entrance to unauthorised persons.

ii) Prohibiting unauthorised persons from handling or

interfering with electrical apparatus.

iii) Giving directions as to the procedure in case of a fire.

iv) Giving directions as to the treatment of persons suffering

from electrical shock.
Page 6 of 13
Spec. No. ADC004 Rev. 02
 1.1.18.4 shall be provided with a framed, indelibly printed single-line
diagram mounted on an easily accessible interior wall. This
diagram shall show all connections between the equipment within
the substation (or MCC room) and external plant, with possible
ring feeds clearly identified as such.

1.2 Switchgear Protection

Switchgear shall be equipped as follows:

1.2.1 Main Surface and Underground Substations

In main surface and underground substations each circuit breaker panel shall be
equipped with a CDG or similar overcurrent and earth fault relay incorporating
shunt tripping and AC series tripping facilities. The shunt tripping coil shall be
actuated from the station battery tripping unit, while the AC tripping coils shall
be directly actuated from the panel current transformers via the O/C and E/F
relay. Particular attention shall be given to ensuring that the current
transformers are suitably rated for the tripping duty.

For major substations, such as main consumer substations and other selected
substations, consideration must be given to the inclusion of light (flashover)
sensitive relays (e.g. Reyrolle “Vamp”) to ensure rapid isolation of power in the
event of a flashover. These relays should be considered for the busbar
compartments and selected (e.g. main incomer) circuit breaker compartments.

Major substations shall also be equipped with two battery tripping units
(BTU’s). The second BTU shall be used to trip a second (backup) shunt trip
coil on the main incoming circuit breakers. Feeder circuit breakers should only
be equipped with one short trip coil, fed from the primary BTU.

1.2.2 Minor Surface and Underground Substations

Minor surface and underground substations may, at the discretion of the Anglo
Platinum Engineer, be equipped for AC series tripping only. This shall be
achieved by the use of series AC tripping versions of a CDG (or equivalent)
relay arranged in conjunction with direct acting trip coils or, alternatively,
where positive discrimination is not essential, by the use of miniature circuit
breakers bridging direct acting trip coils.

1.2.3 Each incomer in a main surface substation shall be fitted with a VAA or
equivalent relay which, when actuated by the fire detection system, trips the
incomer.

1.2.4 Where bus-ducting is led through a firewall, a suitable and effective flame and
explosion barrier shall be inserted within the bus-ducting to prevent the spread
of fire from one section of the switchboard to another.
Page 7 of 13
Spec. No. ADC004 Rev. 02
 1.2.5 All switchgear of voltage rating equal to or greater than 2 kV shall comply with
Electrical Specification AEL-014/AEL-015 as applicable.

1.3 Battery Tripping Units

1.3.1 All battery tripping units shall comply in every respect with the requirements
of Electrical Specification AEL 027.

Batteries shall be of the vented nickel cadmium type or (exceptionally) as

2
approved by the Anglo Platinum Consulting Electrical Engineer, in writing.

1.3.2 The supply to the battery tripping unit shall be derived from a switchboard
voltage transformer. Particular attention shall be given to ensuring that the
voltage transformer is adequately rated for this purpose. All battery tripping
units shall be suitable for powering from alternative supplies of 110 or 220 V
AC. Battery tripping units shall comply with Anglo Platinum specification
AEL 027.

1.3.3 Battery tripping units shall be installed in secure locations and not over cable
ducts where it may be damaged in the event of a cable fire beneath. The
AC supply cable to the battery tripping unit shall be led in armoured cable,
while the DC output cable should preferably be of fire-survival construction.
The minimum cable size for the DC output shall be 10mm² to minimise volt
drop in the cable. The DC cable should be led to the associated switchboard by
the shortest possible safe route and preferably on an overhead rack.

1.4 Transformers

1.4.1 All oil-filled transformers shall comply with the current edition of Electrical
Specification AEL 013 - Distribution Transformers or AEL 018 - Power
Transformers, as applicable.

1.4.2 Notwithstanding the stipulations of the above Electrical Specifications the

following additional requirements shall be observed:

1.4.2.1 Any oil-immersed transformer incorporating a conservator tank

and rated at 1 250 kVA or more shall be equipped with Buchholz
gas and surge protection, the latter relay being arranged to trip the
associated HV breaker while the former shall sound the local alarm
only.

1.4.2.2 All oil-immersed transformers rated at 1 250 kVA or larger shall

be fitted with an explosion vent with integral tripping contact
(Qualitrol or similar). The vent shall be arranged to discharge oil in
a safe direction.

Page 8 of 13
Spec. No. ADC004 Rev. 02
 1.4.2.3 All oil-immersed transformers rated at 1 250 kVA or larger shall
be equipped with a dial thermometer incorporating alarm and trip
contacts which shall be wired into the appropriate relays on the
HV breaker.

1.4.3 The maximum size of a distribution transformer with a secondary voltage of

550V shall not exceed 1 600 kVA. Where possible and feasible within the
dictates of standardisation, transformer capacity should not exceed 1 000 kVA
in order that fault levels may be reduced accordingly. The maximum size of
lighting transformers (380/400V secondary) shall not exceed 150 kVA.

1.5 Fire Protection

Fire Protection shall be installed in all MCC rooms and main surface substations (and
underground substations where their strategic importance renders their necessary).
This protection shall be applied as follows:

1.5.1 Smoke detectors shall be installed in the main volume and in the cable duct or
basement of each room or zone for general fire alarm purposes, the detectors
being divided into two circuits. When a single detector operates, an alarm shall
sound; should a second detector in the other circuit operate, all substation (or
MCC) incomers within the zone shall immediately be tripped and any
ventilating fans stopped.

In addition, in the case of a Consumer Substation, the fire detection system

shall be arranged (where feasible) to trip all Eskom breakers feeding the
Substation, using Eskom's tripping supply in conjunction with a suitable
interposing relay (VAJY or similar).

1.5.2 Each of the two smoke detector circuits shall be equipped with equal numbers of
optical and ionisation detectors, with a minimum of two of each type in each
circuit.

1.5.3 Cable ducts and cable basements in main MCC rooms and main surface
substations shall be equipped with fire extinguishing facilities whereby bulk CO2
shall be arranged to flood the entire duct or basement volume in the event of a
fire being detected in that zone. Cable ducts shall be covered by chequer plate,
and all apertures surrounding cables passing through the floor between the duct
or basement and the room proper shall be sealed with a fire-resistant
compound.

1.5.3.1 Main Consumer Substation

In main consumer substations it is a requirement that all incoming

and outgoing feeder cables are each totally segregated from other
cables, by means of brick or concrete partitioning, across the
respective cable trenches.
Page 9 of 13
Spec. No. ADC004 Rev. 02
 In such circumstances, fire detection within the individual cable
compartments is not required. Detectors should however be
installed in the area directly above the cable compartments, to trip
the incomers and ventilation fans, in a “double knock” arrangement
as detailed in 1.5.1 and 1.5.2 above.

1.5.4 Remote manual operation of the system shall be afforded by means of a

break-glass push button mounted on an external wall adjacent to the main
personnel access door. This push-button shall trip the incomers (as in
Section 1.5.1 above) and operate the fire extinguishing system where provided.

1.5.5 Any main surface substation incorporating oil switchgear and fitted with:

i) a closed ceiling, or

ii) a closed roof not incorporating ample natural ventilation facilities

shall, in addition to the cable duct/basement fire extinguishing system
specified in Section 1.5.3, be provided with a CO2 room flooding
facility.

1.5.6 Fire precautions to be observed in underground substations shall additionally

comply with the relevant section of the Group Fire Prevention Programme.

1.5.7 The fire behaviour characteristics of all cables employed within substations shall
comply with or exceed the requirements of the current Group Specification for
that type of cable.

1.6 Design Deviations

Where specific conditions demand deviation from the requirements stipulated in the
above design code, any such deviation must receive the written approval of the Group
Consulting Electrical Engineer.

1.7 Remotely Interogatable Metering

All major substations shall be equipped with remotely interogatable metering, on all
Eskom Incomers, to facilitate the printing of power consumption reports, in the same
format as the actual power account from Eskom. Major substations are deemed to be
2 all substations which receive power from Eskom including, but not limited to,
concentrators, smelters, fridge plants and shaft heads.

It must be possible to generate and print such reports from any remote location by
means of "dial-up" modems and the associated hardware and software.

Page 10 of 13
Spec. No. ADC004 Rev. 02
2.0 MAINTENANCE

2.1 Fire Protection

2.1.1 All substations must be kept clear of litter and inflammable material and must in
no way be used as a store for any other material. In particular, transformer oil
shall not be stored in substations. Cable ducts shall be maintained in a clean
and oil-free condition.

2.1.2 All substations must be equipped with at least four 9 kg (minimum) stored
pressure dry powder fire extinguishers to SABS 810 and these shall be
inspected, and replaced if necessary, on a monthly basis. These extinguishers
shall be suitable for Class A, Class B and Class C fires.

2.1.3 Automatic fire protection and extinguishing systems shall be tested each month
(with a maximum interval of 45 days between inspections) and the correct
operation of every component verified down to the operation of trip relays and
actuating solenoids. Any temporary bridges and/or open circuits required to
enable these tests to be performed must be removed and the system restored to
operating condition at the conclusion of the procedure. All results shall be
recorded in the substation log book.

In addition each system shall be subject to a comprehensive annual examination

and test by the supplier or his appointed contractor.

2.1.4 Under no circumstances shall cable joints be installed within a substation or

MCC room.

2.1.5 The responsible engineer shall ensure that fire-walls are maintained in an efficient
condition and, in particular, that flame-retardant barriers are intact where cables
pass through internal and external walls.

2.1.6 Every substation shall be subjected to an infra-red inspection at intervals not

exceeding 6 months, and the results recorded in the substation log book. The
report shall be submitted to the responsible engineer for action as necessary.

2.2 Battery Tripping Units

2.2.1 A regular weekly inspection must be carried out on each battery tripping unit,
and the external condition of the unit and the on-load (test) voltage recorded in
a log book dedicated to this function. The log book must be submitted on a
monthly basis to the responsible engineer for countersigning. The voltage
recorded shall be that obtained after the test load has been applied for
5 seconds.

Page 11 of 13
Spec. No. ADC004 Rev. 02
 2.2.2 Batteries shall be replaced on a regular basis, irrespective of apparent condition.
In all cases, exact equivalents must be installed to ensure effective charging
operation is maintained. Batteries must be renewed as follows:

Vented nickel cadmium cells - 10 yearly

Sealed nickel cadmium cells - 5 yearly
Vented lead acid cells - 10 yearly

Where the actual age of a battery is in doubt, it must be replaced immediately.

2.2.3 Where an existing sealed nickel cadmium battery and associated charger is
applied to a main incoming substation on surface or to a major substation
underground (i.e. on a station or pump station) the entire charger and battery
must be replaced with a vented nickel cadmium system complying in all
respects with Electrical Specification AEL 027.

2.3 Transformer Maintenance

2.3.1 Every oil-filled transformer shall have a sample of oil drawn from it annually for
testing by a competent person, at which time the oil level and silica gel breather
condition shall be verified and made good if necessary.

2.3.2 Should the oil investigation noted in Section 2.3.1 indicate that the oil is in poor
condition it shall be purified in situ by a specialist firm.

2.3.3 Any oil leak from a transformer is a serious fire hazard and must be immediately
reported to the responsible engineer and rectified as soon as possible after
detection.

2.3.4 Under no circumstances shall transformers be paralleled onto a busbar without

the appointed responsible engineer having satisfied himself that the secondary
switchgear is adequately rated for the resulting increased fault current. (This
does not preclude brief periods of paralleling required to maintain the supply
during switching operations).

2.4 Switchgear

2.4.1 Oil switchgear located in underground and main surface substations represents a
fire hazard. This switchgear shall be replaced as soon as practicably possible by
vacuum or SF6 equivalents. In the interim the oil content of all OCB's shall be
renewed annually, and the contacts inspected and replaced as necessary.

2.4.2 Primary injection testing of all HV switchgear shall be undertaken every

five years. Secondary injection testing or, alternatively, trip testing by
operation of protection relay contacts shall be carried out annually on all
HV circuit breakers.

Page 12 of 13
Spec. No. ADC004 Rev. 02
 2.4.3 The results of all tests and examinations of HV switchgear shall be recorded in a
log book retained in the substation (See Section 2.5).

2.5 Record Books

The following record books shall be kept within each substation:

2.5.1 Record of operating and maintenance work carried out on substation equipment,
including details of all HV switchgear trips.

Transformer inspections.
Fire extinguisher/fire protection system inspections.
Infra-red inspections.

2.5.2 Log Book for recording of:

Battery tripping unit inspections, and the reporting of the condition of the unit.

All log books shall be signed on a quarterly basis by the responsible engineer. All entries
in log books shall be signed and dated.

2.6 Independent Audits

The electrical installation on each Mine shall be subject to an independent electrical audit
on a regular basis. This audit will normally be carried out by an external engineer
appointed by the Anglo Platinum Management Services, Consulting Electrical Engineer.

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Spec. No. ADC004 Rev. 02