Proconics Successfully Executed a complex H3-SS-01 MV Switchgear Replacement Project.

Our recent H3-SS-01 MV Switchgear Replacement Project was a shining example of the excellence of our construction management and execution teams. From careful planning to flawless implementation, this project once again highlighted why we are leaders in handling intricate engineering challenges.

Project Overview

The H3-SS-01 project presented a unique challenge—replacing the existing medium voltage (MV) switchgear while keeping the plant fully operational. This required a live swing-over of the plant’s electrical load from the old switchgear to the new one, without any interruptions to the plant’s operations. To achieve this, we used an MV mobile substation, which allowed us to transfer loads, one by one, including critical equipment such as motors, transformers, and compressors, ensuring the plant remained fully functional throughout the process.

In the first phase, after transferring the loads to the mobile substation, we replaced the old switchgear, performed a series of MV tests, and conducted bump tests to ensure correct directional accuracy. Once all checks were completed, the equipment was handed back to the plant for commissioning, with all necessary approvals signed off. The same process was successfully repeated for the second phase, ensuring a smooth transition throughout.

Project Highlights

One of the most demanding aspects of this project was removing 136 cubic metres of river sand from the plant’s basement, all done by hand using shovels and wheelbarrows. Being in a basement, we faced restrictions on the use of heavy machinery due to the presence of live underground cables. Despite these challenges, our team executed the task efficiently, taking into account the risks and maintaining full safety compliance.

Safety Milestones

Our commitment to safety remained a top priority throughout the project. The team completed an impressive 31,728 hours with no incidents and spent 145 days on-site without a recordable case. We proudly achieved zero Section 24 incidents, a testament to our strict adherence to safety protocols and the vigilance of our health and safety officers.

Equipment Replaced

The project involved the replacement of several key components, including:

• MV switchgear

• Battery charger and batteries (executed through a live swing-over without causing any control or indication trips, utilising a mobile battery car)

• Auxiliary panels and interface panels

• Busducting

• A remote switching facility for the MV switchgear

Additionally, we completed seven tariffication joints on MV cables, four of which were necessitated by the mobile substation factor. Impressively, there were no failed joints or phase swaps, highlighting our technical expertise and meticulous execution.

Proconics’ Four Pillars of Execution

Our execution strategy was rigorously tested in this project, and we passed with flying colours. Proconics’ four pillars—Safety, Integrity, Schedule, and Cost—were central to every decision we made, ensuring we consistently met and exceeded expectations. The collaboration between our construction, engineering, planning, project management, and safety teams was seamless, enabling the project to be completed on time and within budget.

A Team Effort

This project was a huge success thanks to the dedication and exceptional performance of the entire team. Every individual involved understood their role and executed it brilliantly, from plant support to field execution. Special recognition is due to:

• Christian Human (Project Manager and Engineer)

• Skhumbuzo Thabethe (Engineer)

• Hazel Xhaba (HSE)

• Kobus van Staden (Planning and Scheduling)

Their extraordinary contributions ensured the smooth delivery of this complex project, once again proving that Proconics is truly brilliant at executing intricate EPC projects.

We are incredibly proud of this achievement and look forward to continuing to deliver excellence in all future projects.

Hazel Xhaba’s Post on LinkedIn:

"Yet another one, truly honoured. A Replacement of an MV Switchgear, a very interesting one indeed. I cannot take this one alone. This award goes to the Proconics HSE team for the excellent teamwork that was demonstrated on this project. Know the seven characteristics of an eagle? Then that’s the Proconics HSE Team!

We have vision, we are fearless, we are tenacious, we face challenges as they come, we fly high, we are problem solvers, we nurture our young ones, and lastly, our leaders are not bosses. #ProudProconites #BrillianceExcitesUs!"

Skhumbuzo Thabethe’s Post on LinkedIn:

"Grateful indeed. Learned a lot. Looking forward to more opportunities. Shout out to the A-team 😁 and our client."