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These Package Compact Substations are locally manufactured in the Kingdom of Saudi Arabia by ABB
Electrical Industries Co. Ltd., part of the ABB group world-wide to meet the enironmental conditions of
the Kingdom, neighboring !ulf countries and other similar places for outdoor installations.
The Package Compact Substations are completely self-contained, mounted on an integral base, factory
assembled in a totally enclosed, aesthetically and acceptable cladding, andal-proof, ermin-proof and
weather-proof housing ready for installation into position on a concrete base pad or pier.
The base frame is of welded structural steel and been hot-dipped galani"ed after fabrication to assure
affectie corrosion resistance in serice.
#ousing of the Package Compact Substation is made of special material called A$%&'(K, a sheet steel
with a metallic alloy coating. The alloy consists of ))* aluminum and +,.+* "inc. This proides optimum
corrosion protection.
The housing has three compartments, separated with A$%&'(K sheet. The transformer compartment is
completely separated from the medium oltage and low oltage compartments.
The Package Compact Substation is shipped from the factory ready for installation on site. 't has been
submitted to all normal routine tests before being shipped, and it is not re-uired to do any oltage testing
before putting it into serice, proided the substation has not sustained any damage during transportation.
'mmediately upon receipt of the Package Compact Substation, e.amine them to determine if any damage or
loss was sustained during transit. 'f abuse or rough handling is eident, file a damage claim with carrier
and promptly notify the nearest A// office. A// 0$0CT1'CA$ '(2%ST1'0S C3. $T2. is not
responsible for damage of goods after deliery to the carrier4 howeer, we will lend assistance if notified of
claims.
PERSONNEL SAFET
The first and most important re-uirements are the protection against contact with lie parts during normal
serice as well as maintenance or modifications.
This is the reason why all lie parts hae been metal enclosed, so that when the parts are lie and the
Package Compact Substation doors are open, no one can be able to touch them.
Also, it is safe in case any short-circuiting or sparking occurs at the busbars.
VENTATION
Transformer compartment has been proided with sand trap louers, to preent ingress of sand and that
proper air circulation should take place.
EARNG
Proper earthing busbar has been proided.
PTMV - Medium Voltage Equipment
ABB Electrical Industries Co. Ltd.
Kingdom of audi Ara!ia
ABB
HADLING
$ifting lugs has been proided on top of four corners of the housing for lifting the 2PS by crane and chains
as a single unit, otherwise this can be done by a forklift of sufficient capacity, but the lifting fork must be
positioned under the transformer portion.
INSTALLAIONS
A clean, flat surface capable of supporting the Package Compact Substation unit weight is the
only re-uirement for a foundation. 't is, howeer, important that ade-uate accessibility, entilation
and ease of inspection of the unit must be proided.
'n all installation work, the safety regulations for electrical installations hae to be obsered.
0ach Package Compact edition of '0C or A(S' re-uirements.
The Package Compact Substation is designed to operate with a solidly grounded neutral system.
The neutral connection should be solidly and permanently grounded.
Tap connections
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SAOPERATIONS
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A POOR GROUND EARTHING MAY RESULT IN LOSS OF LIFE OR
DAMAGE TO THEMENT. AN EFFECTIVE LOW RESISTANCE
GROUND IS ESSENTIAL FOR PROPER OPERATION.
TAP CONNECTIONS MAY BE CHANGED ONLY WHEN THE UNIT IS
TOTALLY DE-ENERGIZED.
All units hae taps located in the #igh 8oltage winding. The tap arrangement is shown on the nameplate of
the transformer. These taps are proided to furnish rated output oltage when the input oltage differs from
the rated oltage.
To change tap
handle.
,. 1emoe safety shorts and ground connections from the high oltage and low oltage buses.
After ensuring that no tools or hardware was left in the enclosure, and the enclosures are closed properly,
you may then re-energi"e the Package Compact Substation. 7ake sure that the tap connections are proper
for the re-uired oltage
without placing undue stress on the terminals.
Conductors should be securely fastened in place and ade-uately supported with allowances for e.pansion
and contraction.
FINAL
APressure relay BtrippingC
A3il leel indicator
A0nsure that all fuses are inserted and in the correct position
D E All tap connections are properly positioned.
D E The neutral and ground connections hae been properly made.
Mechanical Inspection
D E All shipping members hae been remoed.
D E There is no obstructions in or near the openings for entilation.
D E (o tools or other articles are left inside the enclosures.
D E All protectie coers are in place or closed and bolted tight.
"AINTENANCE AND PERIODIC INSPECTION
'n order to assure a long lifetime and correct and reliable operation of e-uipment deliered for this facility
it is of utmost importance to perform maintenance regularly.
6ollowing general rules should always be considered before starting maintenance actiity.
5. Authority from responsible engineer shall always be obtained before starting any maintenance.
;. 6ollow safety !"#e$%!e esta&'(s)e$ in carrying out the work.
1eali"e that no set of safety "! *a(+te+a+#e (+st!%#t("+s will eer be written that can ade-uately coer all
accident possibilities.
Therefore #SAFET$# as dictated by actual current conditions, always takes precedence oer any
preiously prepared safety or maintenance instructions. Assume nothing. Take the precautions that you
personally deem necessary in addition to those included in standard practice.
to corrosion.
A The high-pressure spray may damage e-uipment.
A 0specially protectie coatings may be remoed.
Bolt Tightness
All connections should be tight and secure. /olts and nuts on busbar and terminal lugs should be
tor-ued and marked properly.
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Inspection and Testing
The need for preentie maintenance will ary on operating conditions. 9here heay dust conditions e.ist,
an accumulation of dust on the e-uipment may effect the operation of unit substation and its protectie
apparatus.
9hen normal maintenance inspection and cleaning of bus connections, relays, lug connections, and other
part of the distribution system is being made, it is adisable to operate and check circuit breaker or switch-
disconnector operation. The following procedure is highly recommended.
Routine Field Testing
1outine field testing of the electrical e-uipment is intended to enable maintenance personal to determine,
without laboratory conditions or complicated e-uipment, that a particular electrical e-uipment is able to
perform its basic circuit functions.
The following constitutes a guide to tests that might be performed during routine maintenance.
%. Insulation Resistance Test
0.treme atmospheres and conditions may reduce the dielectric withstandability of any insulating
material. An instrument commonly known as FmeggerF is used to perform this test.
The oltage recommended for this test should be at least )G percent greater than the circuit rating4
howeer, a minimum of )GG olts is permissible. Tests should be made between phases of opposite
polarity as well as from current carrying parts of the circuit protectie deice to ground. Also, a
test should be made between the line-and-load terminals with the circuit protectie deice in the
F366F position.
1esistance alues below one megaohm are considered unsafe and should be inestigated for
possible contamination on the surfaces.
NOTE& 6or indiidual circuit protectie deiceHs resistance readings, load and line conductors
should be disconnected. 'f not disconnected, the test measurements will also include the
characteristics of the attached circuits.
A temperature and humidity reading are recommended and recorded during the testing
period.
'nsulation
connections is eident by discoloration or signs of arcing, the connections should be remoed and
the connecting surfaces clean before re-connections. 't is essential that electrical connections be
made properly to preent and reduce oerheating.
'. "ec(anical O)eration
2uring routine tests, mechanical operation of the circuit protectie deices or disconnects should
be checked by turning it F3(F and F366F at least three times.
TRANSFOR"ER "AINTENANCE
Inspection during operation
5. 'nspection of oil leelI when adding oil safety distances hae to be obsered.
;. 'nspection of oil leakage.
,. 'nspection of tra
/efore starting maintenance work, the transformer has to be disconnected from the network and earthed or
grounded. 9hen the disconnector has been opened, one has to see to that they stay open and, before
grounding or earthing, one has to test that they are oltage free, i.e., with a oltage tester.
Ins)ection o* oil lea+s and )recautions to ,e ta+en.
3il leaks may occur as followsI
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5C 6rom bushing gaskets Bif the gasket has become loose, tightening will help4 if the gasket has lost
its elasticity, it has to be replaced. The reason for losing the elasticity can be e.cessie heating or
ageing of the gasketC.
;C 6rom coer gaskets, ales, and gaskets of the off-load tap changer Btightening of the screws or
bolts will usually helpC.
,C 6rom welded Joints Bleaking Joints can be repaired by welding. A skilled welder is needed for the
JobC.
Cleaning to be carried out annuallyI
5C /ushings Bcleaning agent e.g. white spiritC
;C Transformer coer and tank
,C !lasses of relay, thermometer, and oil leel indicator
Surface treatmentI
Surfaces that hae not been inspected during operation, should be checked and the damage
coatings be repaired.
'nspection and maintenance for accessories, protectie and regulating e-uipmentI
5C To preent o.idation of contact surfaces of the off-load tap changer it has to be moed from side
to side a few times, at least once a year.
;C function of alarms and tripping contacts of thermometers.
Inspection Measurements
'n addition to the aboe instructions the following inspection measurement may be carried outI
5. 'nsulation resistance of windings
#8 9inding to
es from the test report. 2ue to inaccuracy of the general-purpose meter a difference of a few
percentages may be possible. 't is adisable to use a transformation ratio bridge for the
measurement.
,. (o-load current
A small oltage fed between each phase and the star point Bin a star connected transformerC ia an
isolating and regulating transformers will result in the reading of a series connected ammeter being
only a ten of milliamperes.
9ith the same oltage reading the current taken by other phases can be measured. The e.citation
currents of different phases should be appro.imately the same magnitude. 'n a damage phase the
current can rise to tens of amperes thus the regulating transformer has to be protected by a suitable
fuse.
+. 2C resistance of windings
A satisfactory large 2C source and an accurate resistance bridge meter are needed for the
resistance measurement. 9hen disconnecting the measuring current instrument dangerous oltage
can be induced. Therefore a skilled person must perform the measurement.
Opening/Resealing Sealed type Transformers
Sealed type transformers must not be opened unnecessarily as this could cause the oil to come out or air to
go in depending on the temperature of the oil. This results in disturbances of the normal pressure ariations
causing increased stress on the tank due to under-pressure or oer-pressures.
9hen opening the transformer, for e.ample to replace a bushing, opening and resealing must be performed
according to these instructions.
r nuts and upper gaskets of all bushings and possible de-airing plugs.
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+C 6ill with oil through oltage bushings until it runs out through the low oltage bushings and
possible de-airing plugs.
)C Tighten the upper nuts of low oltage bushings and de-airing plugs.
=C Continue filling with oil until the high oltage bushings are completely filled.
?C Tighten the upper nuts of high oltage bushings.
Notes
'f the transformer is proided with plug-in bushings the upper nuts are not loosened because these
bushings cannot be bled. 'n this case the transformer is filled through other bushings or filling plug
whicheer is higher.
FSE
"AINTENANCE
6or particulars see 'nstallation, serice and maintenance instructions for $ow-8oltage Circuit /reakers
been used in this substation.
work the following precautions must be followedI
A 3pen the circuit breaker and check that operating mechanism springs are discharged.
A 9ith draw-out ersion circuit breakers, work with the circuit breaker withdrawn from the fi.ed parts
A 6or work on fi.ed parts, turn the supply circuit and au.iliary power circuits off4 also earth the
terminals isibly, on the supply and load side.
!eneral
2uring normal serice the
circuit breakers re-uire
minimum maintenance. The
following program table for
maintenance 8isual e.ternal
check K inspection
3ne year Si. months
check from the outside for dust, dirt, or damage of any kind.
GGGGG
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