operational and maintenance instructions manual for medium and low voltage power control & distribut

7/28/2019 Operational and Maintenance Instructions Manual for Medium and Low Voltage Power Control & Distribut

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Operational & Maintenance Instructions Manual

For Medium/Low Voltage Power Control & DistributionSwitchgears

With instructions for

Protection and Limitation of Environmental Pollution


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Contents

Part One: Companys range of products.ABB Arabs quality and environmental policies

Part Two: Switchgears transportation & storage precautions.

Part three: Installation guide for company products and their supplements.

Part Four: Performing maintenance for medium voltage power distribution & control

boards.

Part Five: Simple and tolerable failure for medium voltage power distribution and

control switchgears and methods of repair.

Part Six: Performing maintenance for low voltages power distribution and control

switchgears.

Part Seven: Simple and tolerable failure for low voltage power distribution and

control switchgears and methods of repair .

Environmental guidelines for clients duringdigging up for cable laying.

Appendices

Checklists forms to assure the integrity of the implemented tasks.


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Introduction

Our Dear clients

Its our pleasure that you trusted and purchased our products.

Regarding the great importance of the simple and the protective

maintenance to preserve the optimum performance and to extend theswitchgears life span, it would be our pleasure to present you this userguide to preserve high effective performance.

This manual contains the best procedures for transporting, installing,

operating, performing the maintenance, and fixing up the simple failureof switchgears.


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ABB Arab Operation & Maintenance Manual5/48

ABB Arab customer service center offers the following services.

1. Installing all switchgears and all their supplements of cables, transformers

supplied and produced by ABB Arab.

2. Supervising the switchgears installation, supplied and produced by ABB

Arab.

3. Offering recommendations to supply the suitable spare parts for all types

of switchgears produced by ABB Arab.

4. Offering the protective maintenance for switchgear.

5. fixing up switchgears in case of failure.

6. Taking the required measurements to improve the power factor andmeasuring the ranks of the loads harmonious and recommending

solutions to remove these harmonious.

7. Performing the measurements among the pre-established paths.

Quality Policy

We, all ABB Arab manpower are one team, our main aim is to execute all theinternal or external customers demands efficiently .

Environmental Policy of ABB Arab

ABB Arab fully perceives its responsibilities and commits the following:

1. Protecting all the environmental elements which might be affected by the

ABB activities also providing and protecting the safety of the entire firmsmanpower.

2. Sticking to all what have been stated in the Egyptian laws concerning theenvironment preservation.

3. The continuous preceding of improving and eliminating the environmentalpolluters.

4. Rationalizing the use of natural resources.

All of which would be verified through the following:

?? Establishing, applying and performing the required maintenance for the

environmental management system according to the internationalenvironmental standards ISO 14001.

?? Performing the international evaluation on the main and subsidiary goalsof the environmental management system.


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Second Part

Precautions should be in consideration in case of transporting and storing

switchgears.

Our Dear Clients

The proper start for operating the switchgears begins once you have received theproducts from our factories thus we found it essential to inform you with the most

precautions you must perform.

Firstly: While transporting switchgears

1- The truck which will transport the switchgear must be appropriated with

the switchgears dimensions (weights) which are attached with theswitchgear).

2- Fixing up the switchgears on the truck with appropriate fixing meanswhich do not cause damage to the switchgears.

e.g.All medium voltage circuit breakers must not be fixed or tightened

through their (arms) where as these circuit breakers have been adjustedon a (jeg) inside the plant and any crookedness or bending happen tothese arms will inhibit the interlock of the breaker into the cubicle during

the setting up, which will lead the breakers poles to be broken down.

3- Up loading the switchboards must be done by using some appropriate

means such as winches whose lifting capacity is greater than theswitchgears weights.

Secondly: Storing the switchgears

Sometimes there is a long duration between the delivery time and theinstallation, therefore, the following precautions must be performed:

1. Do not remove the plastic cover of the switchgear.

2. Do not leave the switchgear in dusty places as dust and dirt badly affect

the functionality of the circuit breakers mechanism.

3. Do not leave the switchgear in humid places, as humidity affects the

switchgear isolated barriers (which may cause collapse later during theoperation).

4. After installing the switchgear in the site, all the cables outlets beneaththe switchgear must be sealed off, especially in the desert site.


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Third Part

The Installation guide book of the companys products & supplements

The contents:

1. Installing a Ring Main Unit.

2. Installing a medium voltage multi cubicles switchgear.

3. Installing a low voltage main switchgear.

4. Installing a transformer kiosk.

5. Installing a power transformer.

6. Installing a terminal box for a medium voltage cable.

7. Installing the cables.

8. Establishing an earthing industrial well.

9. Measuring up the resistance of an earthing industrial well.

10. Installing batteries and preparing an alkali solution.

11. A list for a thoroughly toolbox items for maintenance/installing technicians.

12. Checklist forms for using.


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1- Installing a Ring Main Unit

Site Inspection:

?? The site must be fully inspected and the rooms dimensions must be takento fit the units dimensions and the cable trays beneath the unit and theentire room.

?? Verifying the rooms and the doors highest which allow the unit to rack in.

?? Getting away any obstacles which prevent the trucks to be in the site orprevents the winches from up loading the units.

?? The iron base frames dimensions beneath the unit must be fully

recognized with the same unit dimensions.

Manufacturing units frame

?? The one who is in charge for performing the tasks should fill an analogy

and testing model lists for installing a new frame.

?? The frames required measurements should be known from the single line

diagram.

?? The beams and angels measurements should be taken according to the

required measurements and the auxiliary materials.

?? Transporting the unit with their tools should be after inspecting the site andchecking the existence of power resource there.

?? The tools like the meter , angle , the fork should be used to mold ironaccording to the required measurements.

?? All the iron beams and angles will be cut after marking them up using thecutting disk.

?? All the iron beams and angles should be welded after adjusting upon oneinternal and external horizontal plane.

?? The cleanness of the welding should be checked up by firstly using the

small hammer then by using the cleaning wire brush then use the coneafterward for leveling the surface and finally the surface must be polished

with anti-rusting material.


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?? The place of installation should be leveled by using crushing tools

(hammers gavels -bolts).

?? The frame should be placed on its determined place and will be settled

by using the settling canes.

?? The water scale should be used to adjust the frame from all the directionsthus to be sure that it has been settled on the same sole horizontal plane.

?? Water and cement should be mixed by using the trowel ( ratio will be 6cement frails for every meter square ).

?? The paste should be leveled by using the trimmer and should be left for 5

days till it dries up and become stiff, and then the frame will be ready forinstalling the unit.

Installing the unit

- The one who is in charge for performing the tasks should fill checklist formfor installing a new Ring Main Unit.

- At the site, People who are in charge should receive and bring the unit inby using rolls to the installing room, and there must be full cautions, no

scratching nor damaging the units surfaces or their inner contents.- The unit should be placed on its frame while making sure that it is

vertically and horizontally balanced upon all its corners.

- The unit should be fixed to its frame by welds or rivets

- The device which shows the ground infiltration and the current resource(220 volt) within the room must be connected to the unit by using a thermoplastic wire 2X2 m2 copper

- All the units supplements must be fixed with it.

- All the units elements should be functionally tested.


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Supervising The Ring Main Unit After Installation

The following tasks must be reviewed:-

1. Fixing the unit on its pre-designed frame, by going over the welds or therivets.

2. All the tightens must be tightly closed with the moment wrenches.3. Connecting the ring core which belongs to the earth failure indicator

device.4. The functionality of the load break switches with a suitable tool.5. Connecting the unit with the main earthen network

6. The straps of the controls wires and heaters must be well tighten if found.

7. The fixing of the units bottom covers after installing the cables.8. The connections of current transformer, voltage transformer, voltmeter &

ammeter and all available measurements devices.9. Check and review all polishes after cleaning the unit internally &externally.

2- Installing Medium Voltage Switchgear

Switchgear installation

?? The one who is in charge for performing the tasks should fill a checklistform for medium voltage switchgear installation.

?? At the site, People who are in charge should receive and place in theswitchgear using rolls, and there must be full cautions for not scratching or

damaging the switchgears surfaces or their inner contents.

?? The switchgear should be placed on its frame in the same order as in thesingle line diagram and mechanically assembling its cubicles by the boltswhile making sure that it is vertically and horizontally balanced upon all itscorners.

?? The fiber among each cubicle should be untied from up to down.

?? All the Switchgears internal contents should be well cleaned. before

starting to fix its internal components.

?? The sides fibers and the botching boxes must be fixed.

?? The cylinder must be beveled with a busbar.

?? All the racking in and out of the breakers should be adjusted with the

cubicle

?? The cylinder must well re-fixed

?? Every busbars plastic cover must be fixed with busbar cylinder joint.

?? Earthing joints must be well fixed between cubicles.


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?? Fibers must be fixed within the cubicle starting from upward to cover the

cylinder busbar.

?? Inside the cable-free cubicles , fibers must be fixed

?? The control wires must be assembled (according to the controls copy and

the wires numbers on them)?? After fixing the cables , the floor fibers must be well fixed to prevent

reptiles and rodents from coming in

?? Before testing, all voltage transformers must be disconnected to preventthe test current to pass through it.

?? The control voltage should be rated at 110 Volt (DC or AC) during testing

further to the voltage transformer output. The control voltage should beable to making on/breaking off the breaker and also control and interlock

between the incoming and the coupler of the breaker.

?? All the bonding of the power cables and voltage transformers should be

checked up After all the examinations done by the utility companies.

?? The lower fibers of each cubicle should be fixed to cover the cables.?? All the mechanical parts of the cubicles and the breakers must be greased.

?? All the chick list items of MV breakers periodical maintenance formshould be filled, except item No. 1 should not be filled.

?? All data of Attending starting current check list form should be filled .

?? All data of MV SF6 Circuit Breaker Gas refilling check list forms should

be filled.

?? All data of control performance check list forms should be filled.

Supervising MV Switchgear after installation

The following tasks must be reviewed:-

1. Adjusting the board balance vertically and horizontally.

2. Fixing the board on the iron frame.3. The internal and external cleanliness of the switchgear + the sheet steel

and painting as well.

4. All control wires are connected.5. The outlook efficiency of all the switchgears protection and

measurements devices (Voltammeters , Ammeter, indicating lamps, MCBand push buttons ).

6. Earthing connectors must be well connected with the cubicles and also the

earthing network.

7. Easley rack in/out the cubicles.8. Greasing the mechanical parts in motion.9. Flower box and the fixed contacts must be OK.(good condition)10. Fixing and tightening the fiber of the fixed and the moving section and the

floor as well.


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11. Check the C.Bs mechanical & electrical performance.

12. Check The gas pressures or oil level in the C.Bs according to its type.13. Fixing and tightening the power cables in the switchgear.

14. Check functionally the electrical interlock using an external power source.

15. All data of M.V C.Bs periodical maintenance checklist form should befilled, except step No. 1 should not be filled.

16. All data of Attending starting current check list form should be filled .17. All data of MV SF6 C.Bs Gas refilling check list form should be filled.

18. All data of control performance check list form should be filled.

3- Installing Low Voltage Switchboard

Switchboards frame manufacturing

?? The frame will be manufactured according to the previous mentioned

steps.

Switchboard Installation

?? The one who is in charge for performing the tasks should fill LV

switchgear installation check list form.

?? At the site, People who are in charge should receive and place in the

boards using rolls, and there must be full cautions for not scratching ordamaging the boards surfaces or their inner contents.

?? The switchboard should be placed on its steel frame according to the

single line diagram while making sure that it is vertically and horizontally

balanced upon all its corners.?? All the switchboards parts should be assembled together ( metal sheet

works/ copper/control/function unit)

?? The board should be fixed to its frame by welds or rivets

?? All the control wires should be assembled according to the drawings andnumbering.

?? The switchboards control should be tested assuring the electrical interlockbetween the incomer and coupler.

?? The switchboard mechanical interlock should be tested (in case there is)and make sure it is functionally acting.

?? The incoming cables should be connected to the switchboard .

?? All the functionalities of the boards parts must be examined

?? The supplements included with the board must be settled

?? All items for MV/LV cubicles & C.Bs periodical maintenance chick listform should be filled, except step No. 1 should not be filled.


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Supervising LV Switchboard after Installation

All the following tasks should be reviewed:-

- Adjusting the balance of the board vertically and horizontally- Fixing the switchboard on its prepared base.

- The cleanliness of the board internally/externally, the sheet metal and thecoating.

- All the control wires are connected (if available).- The outlook efficiency of all the control and measurements devices of the

board.

- All the C.Bs should be tested manually.- All the incoming/outgoing cables should be well tight and on the same

phase sequence.- The switchboard is connected to the general earthing network.

- The busduckt bars are installed on the main incoming ( if founded ).- Check functionally the electrical interlock of the switchboard using anexternal power source

- All data for MV cubicles & C.Bs periodical maintenance chick list formshould be filled, except step No. 1 should not be filled.

4- Installing a transformer kiosk

Installing the kiosk

?? The one who is in charge for performing the tasks should fill the data for

Transformer kiosk installation & testing check list form.?? The kiosk should be placed correctly over its base, taking in consideration

the directions of low and medium voltage compartments.?? The horizontal balance of the kiosk should be adjusted by lifting it up with

an iron lever while putting softeners beneath the kiosk.

?? All the kiosks supplements should be installed?? The functional performance of the kiosk must be observed during the

existence of the clients representative and some documents must besigned like (receipting acknowledge , current flow ) for all what have beensettled and without notes.


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5- Installing a power transformer

Tools use:

(winch iron levers)

Procedures:

- Arrange means of transportation, companys car or rented ones.

- Uploading the transformer from the truck by using a winch thus thetransformer wheels should be installed in, before allocating.

- Entering and adjusting the transformer to its prepared location- Review the outlook of the transformers body and its components

especially the Silica Gel color ( blue and white), also review the oil level in

the data tube just to confirm the oil levels validity.

6- Installing a Terminal Box for a Medium Voltage Cable

Tools used:

Measuring tape a saw- welding gas cylinder fully cable hydraulic presswith lugs emery- weld caustic handkerchief (for cleaning) a file cablerasp

Installing Procedures:

- The one who is in charge for performing the tasks should fill LV terminal boxinstallation & testing check list form.

- The box used should be suitable for the cable for both dimensions andvoltage, also it must be according to the standards ( by the sticker tipped on

the box and checking up precisely the installation catalogue) also handsmust be washed carefully.

- The cable must be well fixed then it should be rasped for 60 cm or more

according to the case s gauge- The exterior cover of the cable should be divested by a rasp knife then the

interior steel chamber should be circularly cut off by the saw then ripped outby pair of tongs.

- Remove the internal cover of the cable by peel knife to find the phases arerolled cylindrically with thin copper tape.


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- Mark17 cm just from the cable, then the copper layer will be cut off and the

semiconductor layer will be removed.- The shield should be welded with the copper belt from its starting end after

emery the three phases then put it a long with the cable thus to be come out

the box- For the semiconductor layer, a suitable tool must be used like (cable rasp) to

remove it out, then emery the phases till the phases surface is smooth again.- The yellow rubber tape (available in the box) should be rolled over with the

start end of the copper in the same rolling direction.- 8 cm of the copper tape and carbon paper of the cable phases should be

polished with Vaseline (comes with the box) .

- The black case must be fixed at the cable start end and covers the copperstart end.

- The black case should be heated with welding gun and the flame should beadjusted to be tranquil with yellowish front part, where as the gun should be

directed to the contraction direction to fasting the shrinking.- Before installing the tri-box , an adhesive tape should be stick on the cableover/above the shield.

- The tri-box should be installed in the cable till the end of the phases then itshould be flamed with the welding gun as shown in step (11)

- Before fixing the terminal, a piece of the isolator should be cut the same long

of the terminal, and the terminal will be pressed in the middle just 1cm fromits beginning

- The rubber tape should be starched such that its new width must be half itsoriginal one, then it should be rolled on the terminals such to be put half uponhalf

- The long red case should be set on the cable and weld with the gun just asthe later

- After the case has been shrunk , it must been checked up for making surethat there are no air bubbles, wrinkles or cold spots

Note: colors of the phases must be cautioned for unification


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7- Installing the Cables

Tools used:

Measuring tape cable scissors or a saw cable press a suitable cablelifting up method (if necessary)

Installing Procedures:

- The cables measurement will be taken with the tape- The required measure will be cut off by a sow or scissors- Cables will then be lined in their pre-fixed paths

- in the case of pleating the cables , the radius of the pleat must be graterthen or equal 6 times of the cables diameter

- An adequate terminal should be used for the conductors sector and typeand it should be pressed down with the piston

8- Establishing an Industrial Earthing Well

The one who is in charge for performing the tasks should fill a check list and testingmodel lists for installing a terrestrial industrial well.

(A) Earthingwell with bayonets

1- Tools used:Digging bridle Axe lever an electrical drill with bonds- a hacksaw with

its cutters a sledge 10 KG- a hammer an ordinary and toothed wrench17 cable hydraulic press with lugs- measuring tape- pair of tongs- wire

ripper trowels sharpen earth resistance measuring device.

2- Required Materials

2-1 Required bayonets according to the works requirements

2-2 insolated copper wire (50:70:95:120) mm according to the clients demands2-3 copper terminal according to the required length of the cable

2-4 rivets 10X40mm2-5 inspection rooms cover +100 bricks + scuttle of cement + 2 scuttles of

sand + scuttle of gravels.


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3-Work Procedures:

3-1 the site and the location of the well must be fully inspected in advanceso that it will never conflicts with the streets , underground pipes or

buried cable paths and it would rather be near a continuous waterresource.

3-2 clay earth must be dug for 80 cm and 125 cm for deserted one beforestart hammering the bayonet

3-3 the bayonet will be hammered till it reaches 20 cm under the earth

level3-4 the pit then will be refilled up with earth till 50 cm under the earth level

3-5 the bayonets edges should be cut with the saw3-6 the bayonets surface must be drilled to make 2 holes with diameter

11mm

3-7 the floor must be lined with a concrete layer of 10mm thickness3-8 using the bricks to build up the examination room then frying it from in

and out, and making holes in it for letting the wires get out from it3-9 the cover of the examination room which is made of cast iron will be

fixed 3cm above earth

3-10 the ground wires will be lined and fixed on the bayonet after attachingits ends with copper terminals

3-11 the resistance of the terrestrial well must be measured and defining thereal value of the well resistance

(B) Earthing well with copper palette

1- Tools used:

Digging bridle Axe lever an electrical drill with bonds- a hacksaw with

its cutters a sledge 10 KG- a hammer an ordinary and toothed wrench17 cable hydraulic press with lugs- measuring tape- pair of tongs- wireripper trowels sharpen earth resistance measuring device zonba

allam a board of oak -5 meters of a rope

2- Required Materials

2-1 a copper palette 100X100X 0.3 cm according to the worksrequirements.

2-2 copper frond 10X30mm 3m length.

2-3 stainless steel tube of 2 diameter and 2 meter length.2-4 100 Kg of Coke.2-5 250 Kg Rashidian Salt.2-6 uncovered copper wire (50:70:95:120) mm according to the clients

demands.2-7 copper terminal according to the required length of the cable.

2-8 Rivets 10X40mm.2-9 examination rooms cover +100 bricks + scuttle of cement + 2 scuttles of

sand + scuttle of gravels + 2 sheets of emery.


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3- Work Procedures:

3-1 The site and the location of the well must be fully inspected in

advance so that it will never conflicts with the streets , underground

pipes or buried cable paths and it would rather be near a continuouswater resource.

3-2 Ordinary employment would be hired to dig the well of dimensions1.5X1.5X2.5 meter for soft earth and 2X2X3 for tough earth

3-3 The well should be well sprinkled with water3-4 The copper palettes surface must be drilled to make 3 holes, the first

is 10 cm from the edge, the second in the middle and the last first is

10 cm from the other edge3-5 The copper frond must be drilled from one of its sides to make 3

holes with the same dimensions of the palette, and from the otherside 5 holes with 4 cm between each and other with the first at 2cm

form the edge3-6 The emery must be used well on both the palette and the frond3-7 The palette and the frond will be liked together by using the rivets

10X40mm with all their parts3-8 Both the coke and salt must be mixed together very well, then a layer

of the mixer must be put under the well at the whole level of earth

3-9 The palette and the frond will be put over the mixer then anotherlayer of the mixer will be put over them

3-10 The stainless steel tube must be fixed on the copper frond at thebottom of the well and even before the earth level with about 35 Cm

3-11 The well must be refilled with earth till its middle then it must be

exposed well to water then the rest of the well must be refilled withearth till 50 cm beneath the earth surface

3-12 Concrete must be poured over the well with thickness of 10 cm thenthe examination room will be built with dimensions of 50X50 cm andheight of 35 cm then lining it from in and out, and making holes in it

for letting the wires get out from it3-13 The cover of the examination room which is made of cast iron will be

fixed 3cm above earth and will be fixed with concrete3-14 The ground wires will be lined and fixed on the bayonet after

attaching its ends with copper terminals

3-15 The resistance of the terrestrial well must be measured and definingthe real value of the well resistance


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9- Measuring up the Resistance of an

Earthing Manmade well

1- Tools used:

- A device uses to measure the earth resistance- 2 iron bayonets made for this- 2 mm copper wires made for this

- hammer- An ordinary 13 mm wrench

- measuring tape

Work Procedures:

- checking the power of batteries within the measuring device

- setting the device on a table about 5 meters far from the well- hammering down the first bayonets 20 m from the well and the second 40- conducting the copper wire with each bayonets and connecting it with the

device- conducting 2 copper wires with the same length to the well and connecting

the other terminals with the device- by pushing the button the measuring will start and changing the resistance

values till reaching the point of balance at which the displayed value will

be equal to the earth resistance value

10 Instructions for Installing batteries and preparingalkali solution

1- The required amounts of salts to a set of batteries 100 Amp. /hour

Amount Unit Description

45 Kg Potassium hydroxide

4 Kg Lithium hydroxide

115 liter Distilled Water

2- Tools required to form the solution

2-1 Hydrometer2-2 A plastic container

2-3 A plastic cone2-4 Pair of plastic gloves for skin protection2-5 Clean plastic or wooden stick

2-6 A plastic jar 20 liter of distilled water.2-7 2 metallic poles.


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Procedures of forming the solution

2-8 Pouring the water into a large and clean container.

2-9 Adding salt to water (not vise versa VERY IMPORTANT).

2-10 Turning the solution over with non metal stick.2-11 The solutions temperature might reach 110? C.

2-12 The solution must be left to cool and its density must b adjusted to be1.19+.002 at 20? C.

2-20 Density can be adjusted by adding little amount of salt or distilledwater in case of over or under requirements of density.

Procedures of installing the batteries to work

2-21 The polarity of each battery must be checked2-22 The battery will be filled till its upper limit

2-23 The battery will then be connected to the charger and will be chargedtill it reaches the Boost mode for 12 hours

2-24 he battery then must be discharged by 2 wired metal poles (50 mm2)during the same solution or drinking water resistance by dipping thetwo poles into the water and connection one of the poles with the

batterys beginning and the other with its end(NOTE: there will be a large spark in the moment of discharging )

the batteries must be recharged again as previously maintained.


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Contents of a consummate toolbox for a filing technician

(Mechanics)

No Type & kind of the tool Q Notes

1 Set of ordinary wrenches 1 12 pieces (6:32 mm)

2 Set of toothed wrenches 1 12 pieces (6:32 mm)

3 Set of Alan wrenches 1 12 pieces (2 :17 mm)

4 Set of Alan wrenchs bits 1 7 pieces (4:17 mm)

5 Set of revolvers bits 1 6 pieces (8 :19)

6 Set of screwdrivers 1 5 pieces-different sizes

7 Set of large props 1 7 pieces (5:10)

8 Straight pliers 2 8,6

9 Flexed pliers 2 8,6

10 Straight pliers 1 6

11 Internal opening pliers 1 6

12 Doggy pliers 1

13 Goosed head straight pliers 1

14 Backed foot 1

15 Measuring filler 1

16 Measuring meter 1 5 meters long

17 Set of multiple files 3

18 French wrench 2 10,6

19 Smith hammer 2 , 1/5 Kg

20 Plastic hammer 1

21 Estensal wrench 1 12

22 Tighten hand for bits 1

23 Tighten hand joint 2 Long and short

24 Full set of short bits 1 Full Set

25 Small water scale 1

26 Set of bonds 20 Different sizes

27 Set of gathering the tulipcontact

Special Set


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Contents of a consummate toolbox for a (electrical) technician

No. Type and kind of the tool Q Notes

1 Set of ordinary wrenches 1 12 pieces (6:32 mm)2 Set of toothed wrenches 1 12 pieces (6:32 mm)

3 Set of Alan Keys 1 12 pieces (2 :17 mm)

4 Set of Alan Keys bits 1 7 pieces (4:17 mm)

5 Set of revolvers bits 1 6 pieces (8 :19)

6 Set of screwdrivers 1 5 pieces-different sizes

7 Voltammeter 1 For measuring the volt

8 Sanding box ( collection ) 1

9Wires peeler

1

10 Ordinary straight pliers 1

11 Wire shatter 1

12 Sanding Piston (presser ) 1

13 Measuring tape 5 meters 1

14 Smith hammer 2 , 1/5 Kg

15 Plastic hammer 1

16 Tighten hand for bits 1

17 Tighten hand joint 2 Short and long

18 Full set of short bits 1 Small

Commonly used tools

1- Air blower2- Electrical driller


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Contents of a consummate toolbox for installing technician

No Type and kind of the tool Q Notes

1 Tool bag 1

2 Small test wrench 1

3 Big test wrench 14 Water scale 30cm 1 German5 Saw frame 1 English6 Set of pipes 1 3pieces (13:19mm)7 Concrete liner 1 Small8 Set of ordinary wrenches 1 8 pieces9 Set of short Alan 1 10 pieces (2:12 mm)10 Set of large Alan 1 10 pieces (2:12 mm)11 Alan wrench 1 17 mm12 French wrench 1 1213 Reversible sparks spectacles 1

14 Welder 1 0.75 Kg15 Isolated nipper 1 816 Isolated shatter 1 617 Methyl pliers 1 1018 Hammer 2 1.5 kg19 Smith hammer 1 0.5 kg20 Smith hammer 1 .025 kg21 Concrete breaker bond 2 1222 Bricks breaker 2 1223 Isolated Wires peeler 1

24 Marking angle 125 Set of mouse tail filers 1 3 pieces (6:8:10)26 Set of flatted filers 1 3 pieces (6:8:10)27 Set of semi-sphere filers 1 3 pieces (6:8:10)28 Large crossed screwdriver 1 Full iron square29 Large ordinary screwdriver 1 Full iron square30 Set of props 1 12 pieces31 Opening pliers 1 732 Tighten pliers 1 733 Measuring tape 1 5 meters34 Set of toothed wrenches 1 12 pieces

35 Set of ordinary wrenches 1 12 pieces36 Sanding pliers 1

37 Doggy pliers 1 1038 Estensal wrench 1 12

Commonly installing used tools

1- inner terminal cable press 5- welding trance2- air blower 6- welding trance3- electrical driller 7- cutting disc

4- cable scissors 8- rocket


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Fourth Part

Technical instructions for performing periodical maintenance on the medium

voltage switchgears

Technicians who are responsible of performing the maintenance on cubicles and

medium volt breakers should follow the following instructions:

A- Preparing the maintenance tools, which are

1- A complete tool box2- Air blower

3- Cleaning forms4- Greases

5- Medium volt test stick6- Special tool for cables tighten7- Prams out hands for all types of breakers

B- Following the safety rules:

Before starting any cubicles maintenance the following instructions shouldbe followed:

1. Putting on the safety helmet and wearing the safety shoes2. Cutting off the power

3. Making sure that nobody else can put on the power4. Testing ins and outs cables to make sure that there is no voltage5. Connecting the bar with the earthly

6. Covering the equipments which may conduct electricity during themaintenance

7. It should be confirmed that all the power is off and there us no voltagefrom any power resource and this is by testing with the testing stick (thetower) and after making sure of the earthly status whether it was a switch

or tighten set.


25/48


C- How to do a periodical maintenance of the cubicles

All the breakers should be brought out from the cubicles ,and then all the powercables should be measured such to make sure that there is no return back

current , then the following must be done :

1- Separating the fixed and moving shutter

2- cleaning up the busbar room and supports using the air blower3- Cleaning up the busbars upper flower box

4- Cleaning up the busbars lower holder5- Cleaning up the current and voltage transformers according to each

cubicles function

6- Cleaning up the whole cubicle.7- in the case of cylindrical busbar, the cover should be separated or all the descends should be

rejoined according to the tights values table8- rejoining the busbars support with the busbars upper flower box

according to the tights values table9- Rejoining the fixed contact of the cubicle l (the busbars upperflower box)

10- Rejoining the current transformers according to the tights valuestable

11- reconnecting the connections of the current transformer control

12- Rejoining the current transformer with the busbars flower boxaccording to the tights values table

13- Rejoining the current transformer with the cable flower box cupperaccording to the tights values table

14- Rejoining the busbars lower holder according to the tights values

table15- Rejoining the fixed contact of the cubicle (the busbars lower

holder) according to the tights values table16- making sure of making earthly switch and how to plug them on and

off

17- running over the connection of the heaters with the cubicles (offound)

18- Running over the connection of the earthly with the cubiclesaccording to the tights values table

19- Running over the connection of the side lock of the breaker

among the two sides of the cubicle20 - Running over the connection ring upon the breaker and making

sure that it is valid and contains no crooks21- Cleaning up the cubicles control room and running over the control

connection within the cubicles control room

22- Making sure that all the equipments of the control room technicallyrun properly (MCB key-timer-contactors relays, ..)

23- Reconnecting the wires with the roses24- making sure that the wires are lying in their paths and they are

covered.


26/48


D- How to do a periodical maintenance to breakers

1. Separating the breakers front door

2. Making a comprehensive cleaning for all the barkers

3. Checking up the oil level or gas pressure according to the kind ofthe breaker

4. Performing the maintenance on the mechanical group ( cleaning greasing oiling )

5. Adjusting the interspaces of the mechanical group according to thetechnical catalogues

6. Running over the functionality of the moving parts within the

mechanical group7. Testing the files of plugging , unplugging ,plugging hindrances and

the breaker at the testing mood8. Testing up the breakers motor

9. Testing up the functionality of the mechanical aids points of thebreaker10. Testing up the functionality of plugging and unplugging the breaker

11. Testing up the in and out position of breakers from/to the cubicle12. Final testing of the breaker within the cubicle to adjust the

mechanical interlock of the breaker

13. Testing up the functionality of control circuit while having thebreaker on operating mood within the cubicle

14. All the tighten points should be left up from the cubicles orunplugging the earthly switches

15. Putting all the breakers within the cubicles such that all the entering

and joining breakers will be right placed16. Making sure that there is no tools on the cubicle or the breaker

such to avoid a short circuit17. The site should be admitted to the engineer on charge and power

should be flowed fort the entering breakers

18. If the clients demanded to flow the power on the exiting breakers,this will happened among his occurrence and supervision

19. All the tasks which have been performed should be signed up in adelivery form such that all the work done with the client would bemaintained.


27/48

ABB Arab Operation & Maintenance Manual 27/48

Fifth Part1 Medium Voltage Cubicles Common failure and how to fix

Failure Description Reasons of the Failure Way of Detection Way of Fixing1 ??The breaker doesnt accept

to be switched on via the

push button on the devicesdoor ( the breaker could betemporary operatedthrough the connectingpush button in thebreakers front part)

??Disconnect the cubiclecontrol via the MCB in the

measurementscompartment.??No voltage on the operating

coil

??Damage in the operatingcoil

??Socket & plug are not wellconnected

??External check-up

??Measure the operating

applied voltage ob theoperation coil.

??External check-up(inflation in the coil)

??Check through the holebeneath the device room

??Connect the cubicles control viathe MCB in measuring

compartment??Check the cubicles control??Change the operating coil

??Connect well the plug with thesocket.

2 The breaker doesnt shut offvia the push button ( thebreaker can be temporallyoperated via the push buttonon front )

??Disconnect of the cubiclescontrol through the MCB

??damage of the disconnectioncoil

??General check up??General checkup

(inflation in the coil)

??Connect of the cubicles controlthrough the MCB

??Replace the disconnecting coil

3 The breaker racks hardly inthe cubicle

??horizontal & vertical plans ofthe cubicles are not adjusted

??the damage on the panels

moving wheel due to badground floor

??Adjust the horizontal &vertical plans of thecubicles by a water scale

??General check up

??Adjust the floor and re-fix theswitchgear on an iron frame

??Change the wheel and adjust theground floor

4 No volt on the control circuitsthough there is on the cables

??The Potential transformersfuses are not well plugged

??General check up ??Plug the Potential transformersfuses


28/48


2 Medium Voltage Cubicles Common Failure and How to Fix

No Failure description Reasons of the failure Way of detection Way of fixing5 ??The breaker is in trip

position when connected??There is a rush current within

the transformer.

??Damage in cable between thetransformers and the cubicle

??Disconnection of the protectionrelay

Making sure of:??Fully isolate the

transformers oil??integrity of the

transformers coil??Adjust values for

overload / short circuitrelay.

??Integrity of cablebetween the transformerand the cubicle

??Relays values for voltageraise / fall

??Refine the transformers oil.

??Fix the transformer coils.

??Adjust the relay.

??Replace the cable.

??Adjust the raise/fall voltage rela

6 The breaker doesnt operatevia the push button + hearinga tone

??The breakers spring is notcharged

??Damage in the anti connectioncoil

??The moving knob is not in rightposition.

??Charge motors breakeris disconnected

??Dust covers the charge-end switch

??Inflation in the coil

??It must be moved clockwisely to its path.

??Connect it

??Clean the switch from dust.

??Replace the anti-plugging coil

??Grease the groove of the movingknob

7 The breaker works for a whilethen disconnect

??The values of the relays arenot proportionally adjustedCTs & loads values

??Read & record the relaysitting values

??Adjust the relay proportionallywith value of load current & thetransformers fixed on thecubicles


29/48


3 Medium Voltage Cubicles Common Failure and How to Fix

No Failure Description Reasons of the Failure Way of Detection Way of Fixing8 The ATS doesnt work

properly??Timers are adjusted for short

time durations , thus timevalues must be longer thentime needs to recharge the

breakers motor.

??Make sure of connecting themoving and the fixed plugs inthe cubicle.

??Damage in one of the circuitscomponents

??Read the timers values

??Push down the movingand fixed plugs beforethe breaker racks into thecubicle.

??Call ABB ARAB servicecenter

??Adjust the timer to 10 seconds.

??Push down the moving and fixedplugs before the breaker racksinto the cubicle.

??Call ABB ARAB service center

9 Hearing sound within thecubicles

??Dust on surface??Humidity in the cubicles

??Clean the surfaces??Make sure about adjusting the

hygrostats values.??Confirm connecting and

operating heaters.

10 Hotness within the cubicles ??Loosens of the contact joints

on the main & sub busbar.

??Confirm that values of all

connections in cubicles areaccording to the momentumvalues in the manual.


30/48


Sixth Part

Performing the maintenance on low voltage Switchgear

Firstly: Low Voltage Cubicles Maintenance

Introduction:

The scheduled duration for performing the periodical maintenance:-

Once every six months or once a year :

for switchgears which are rarely in use while taking in consideration that the breakershould not be left in the plugging mode for more then six months without being

unplugged , thus the mechanism might turn to be slow and the connecting nodesmight need to be cleaned.

Once a month or once every three months:

In case of continuous operation

1- Tasks that must be done during the periodical maintenance

?? Cleaning up

?? Readjustment?? Tighten the nails?? Greasing

?? Test the functionality2- Tools that are oriented for maintenance

?? A complete tool box?? Air blower?? Cleaning forms

?? Greases?? testing stick

?? Special tool for cables tighten3- Cleaning Equipments

?? Air source for vacuuming or blower

?? Cloth ( soft not fabric not synthetic not colored noreuse for the unclean cloth)

?? Detergent (Tricolor Ethan carob tetra chloride ) for movingdown greases , oils and charcoal from the connecting andanti-rusting surfaces

Note: Neither petroleum nor alcoholic based materials should be used in

cleaning

Joining up table

Joining tools Joining values

Rivet 8mm 15 Newton meter





31/48


4-Cubicles Maintenance

Steps of performing the cleaning up:

1- The current should be disconnecting before starting cleaning up2- Using the air blower to cleaning the pass bar

3- Cleaning up the low voltage isolators which carry the pass bar4- Cleaning up the whole cubicle

Steps of tighten up:

1- The values in the table will be used to tighten up by using the momentumwrench according to the Joining up tables values

2- Retighten the pass bars parts by using the Joining up tables values

3- Rejoining the fixed contact in the cubicle according to the Joining uptables values

4- Rejoining the controls wires

Steps of testing up the functionality:

By running over the following:

1. The mechanical movement of the cubicles parts2. The control connections in the cubicles3. All the parts are working properly ( MCB key contact warts- timer relays)

4. The tighten of the wires with the rosettes5. The returning of the wires to their channels and covering them

Secondly: performing the maintenance on the boards components

1- Maintenance Method For The Low Voltage Air Breakers

Before performing the maintenance for the breakers, the

following must be taken in consideration:

1- Disconnect the breaker that has to be checked & maintained.

2- Disconnect the main feeding source from the switchgear.

When and how the maintenance should be performed according to the different

operating status?

Operating status Maintenance program Duration

Normal Performing an external

check then cleaning upthe dust

Once per year at least

Breakers are working in dusty

climate ,high % of humidity, &temp. and vibrate during

operating

The same maintenance

program as the nextclause

Once per six months at

least

After a shortage takes placeon the breaker

Check the main contact &the sparking room asstated in the next clause

Before putting thebreaker on operationanother time


32/48


Details of performing general maintenance on the breakers parts

No The part requiresmaintenance

Checking up result Method of performingthe maintenance

1 - The breakers outer

body

- Existing of dust and

dirt on the breaker

- Blowing out the dust by

using the air blower andthe dirt by using a cleanand dry piece of cloth

2 - Connecting nodesbetween the breakersand the joints ( brass

cables)

- Rivets and nuts arenot well tighten

- The nodes are

oxidized

- Tighten up with amomentum wrench

- Removing the oxidizing

with a very fine emery

3 -The breakers

mechanism

- A resistance in the

operation ofconnecting and

disconnecting thebreaker

- The breakers face must

be separated andcleaned up and greasing

the mechanical group

4 - The breakers maincontact

- Covered with dust anddirt

- The contact surface mustbe cleaned with fine

material (fine emery)

5 - The outer body of thesparking extinguishmentroom

- There are zigzags onthe rooms surface

- It must be replaced

6 -The metal part of thesparking extinguishmentroom

- Covered with dust - Blowing out the dust fromit by using the air blower

Greasing the mechanism: the cleaning up for the metal parts of the mechanism must

be done by using the air blower and a clean piece of cloth. The grease in use issynthetic of lithium model; the breaker must be disconnected and connected more then

one time after greasing it and before letting the current flow on it.


33/48

ABB Arab Operation & Maintenance Manual 33/

Different Failure For Low Voltage Air Breakers and Methods For Fixing.

Expected Failure Breaker doesnt accept to be plugged onBreaker doesnt accept to be disconnected

Breaker makes a contentious disconnecting

An over heat on the connectionsAn over heat on the main contact

The mechanical auxiliary contact doesnt perform well

Failureprobabilities

Ways of checking upthe failure

Ways of fixing up thefailure

There is no voltage

sources on theterminals of thevoltage falls coil

There is no voltage

sources on the terminalsof the voltage falls coil

There is no voltage sources

on the terminals of thevoltage falls coil

*

There is voltage


checking up the voltage

source

removing out the voltage

resource*

Plugging coil doesntperform well

checking up the coilsmovement

Cleaning up and removingobstaclesReplacing the coil if spoiled

*

The thermal relaywas disconnected

since a short while

. wait few minutes then tryplugging again

*

Failure in thebreakersmechanism

.. Call ABB Arab servicecenter

* *

Disconnecting coil is

not performing well

Rechecking the coil

movement

Cleaning up and removing

obstaclesReplacing the coil if spoiled

*

Over heating on the

main contact

. Making sure that the

tightening is according tothe momentum values.

*

The relay is not welladjusted

Measuring the real loads well adjusting the relay withrespect to the load

*

thermal relay is notappropriate with the

loads


*

Over heating on theconnections

.. Making sure that thetightening is according tothe momentum values.

*

Over heating on the

main contact of thebreaker

Making sure that the


*

Wrong connectingfor the mechanical

auxiliary contact

The automatic circuitdoesnt work (if found)

Signs lamps dont work

Rechecking theconnections according to

the design of the control.Retighten the wires

*

Over heating on themain contact of the

breaker

Making sure that thetightening is according to

the momentum values.

*


34/48

ABB Arab Operation & Maintenance Manual 34/

Different Failure For Low Voltage Air Breakers and Methods For Fixing.

Expected Failure Breaker doesnt accept to be plugged onBreaker doesnt accept to be disconnected

Breaker makes a contentious disconnecting

An over heat on the connectionsAn over heat on the main contact

The mechanical auxiliary contact doesnt perform well

Failureprobabilities

Ways of checking upthe failure

Ways of fixing up thefailure

There is no voltage


There is no voltage

sources on the terminalsof the voltage falls coil

There is no voltage sources

on the terminals of thevoltage falls coil

*

There is voltage


checking up the voltage

source

removing out the voltage

resource*

Plugging coil doesntperform well

checking up the coilsmovement

Cleaning up and removingobstaclesReplacing the coil if spoiled

*

The thermal relaywas disconnected

since a short while

. wait few minutes then tryplugging again

*

Failure in thebreakersmechanism

.. Call ABB Arab servicecenter

* *

Disconnecting coil is

not performing well

Rechecking the coil

movement

Cleaning up and removing

obstaclesReplacing the coil if spoiled

*

Over heating on the

main contact

. Making sure that the


*

The relay is not welladjusted


*

thermal relay is notappropriate with the

loads


*

Over heating on theconnections

.. Making sure that thetightening is according tothe momentum values.

*

Over heating on the

main contact of thebreaker

Making sure that the


*

Wrong connectingfor the mechanical

auxiliary contact

The automatic circuitdoesnt work (if found)

Signs lamps dont work

Rechecking theconnections according to

the design of the control.Retighten the wires

*

Over heating on themain contact of the

breaker

Making sure that thetightening is according to

the momentum values.

*


35/48


2- Ways of Performing Maintenance For Low Voltage Contactors

Before maintenance, make sure of the following:

1- disconnect the main source for power.2- disconnect the contractor that has to be examined and maintained

When and how the maintenance will be performed on the contractors

according to the different operating status:

operating status Maintenance program Duration

Normal Performing an external

check then cleaning upthe dust

Once per year at least

Contractors work in dusty

climate, high % of humidity& high temp. and vibrate

during operating

Same maintenance

program as the nextclause

Once per six months at

least

Details of performing general maintenance on contactors parts

S Part requires

maintenance

Checking up result Maintenance methods

1 the contactors outerbody

-existing of dust and dirton the contactor

blowing out the dust byusing the air blower and the

dirt by using a clean and dry

piece of cloth2 Connecting nodes

between the contactorand the joints ( brass cables)

Rivets and nuts are not

well tightenThe nodes are oxidized

Tighten up with a

momentum wrenchRemoving the oxidizing witha very fine emery

3 The contactors maincontact

Covered with dust and dirt The contact surface mustbe cleaned with fine

material (fine emery)


36/48


Expected failure, reasons and ways of fixing, for power factor correction Units

No Failure description Reasons of occurring Way of fixing

1 The regulator doesnt

output units thoughthere are loads on the

boards

-Wrong connection.

-Wrong in adjusting theC/K values.

- Low calculated current to

be distinguished by thedevice. This value is

defined for every devicein the catalogue.

- Adjust the time durationjust before operating.

- Check the device in the

automatic position.- Confirm connecting the

C.T e.g. C.T is on the Rposition and the voltages

terminals are on S&Tposition.

- Adjust the C/K value.

- Recheck the C.T % & thevalue of the real

calculated current

- Wait for adjusted the timeduration

2 The power factor

doesnt reach thedevice adjusted value

Very low power factor in

spite of high ratedcapacitors and very lowload current.

- Fixing some capacitors for

no load situation.- Reduce the set rated

capacity

(50KVAR~25KVAR)

3 The regulator signsthat there are units at

service but the

contactors are in OFFposition

- Wrong connection

- Wrong connection

between the C.T and theelectronic regulator

- Check contactorsconnections

- Check regulator outlets.

- Total loads ( load current+ capacitors current )

should pass within currenttransformer

4 All units at service and

the power factor is stilllow

Wrong C.T installation

No fuses are available or

fuses are blown up.

-Make sure that C.T

installation is in the rightposition according to thedrawings.

-Replace the damagedfuses

5 - Blown up of the fuses (

or disconnecting thebreakers ) which are

placed on thecapacitors unitsdrawers.

- High ring tone on themain breaker of the

Capacitor banks- Capacitors burning up

-There are load

harmonics.-(High distortion in the sine

wave of the current andthe voltage)

- Filters must be installed to

prevent the effect of theseharmonious.


37/48


General instructions after low / medium voltage Switchgear maintenance

After the maintenance and when starting operating the electric boards, where the plugs

are plugged automatically (with timer), the operating selection key (manual /automatic)

must be on (manual) position, in order to avoid connecting the controls voltage with theplugging coils before the breakers are ready for work .

Manual operating must be tested after racking the breakers inside the cubicles,operating key can be on (automatic) position or according to the clients wish.

Environmental instructions while digging up for cable laying

Our dear Client

We adjure you to take the following instructions in consideration while

Digging up for cable laying, thus to preserve the environment and the safety of yourmanpower:

1. All the diggers must be announced to wear safety shoes, dust protector, eyesprotector, head caps for sun protection and of course these must be availablefor their use

2. It must be made sure of ( from a specialized authority ) that the digging path isfree from any pipes, gas, water, oil or electricity lines, and in case of existing of

these lines in the digging path all the conditions of the specialized authorityshould be followed to go on digging while these lines are there.

3. All the digging tools must be according with the environmental conditions

4. All the digging wastes should be carried to main dumps or in waste collectingareas while stressing on not polluting environment and roads while transmitting

5. ABB ARAB is sharing you the serious pursuing to preserve all theenvironments elements and we are honored to inform you that we have astrong system for environment and quality management according to the

requirements of ISO 9001 and ISO 14001.

We whish you joy and health with lots of respects and thanks

ABB ARAB


38/48


Check list form for installing Ring Main Unit

Clients name .. File number ...

A ( ? ) will be marked for the steps that has been executed and a (X) will be marked forthe other steps.

Tasks required Result Examination Result

1 Adjust setting 0 level for

R.M.U

Using a water scale

2 Fix up the R.M.U on theframe

General check for theline wildings and thebuts.

3 Connect earth failure

indicator & its C.T.

Check up the

connections4 Install all supplements

supplied with the R.M.UBy observing

Function test of the R.M.Us

components by pluggingand unplugging the

switches

Check the integrity of

the mechanism andprecise contact

connection.

Device name .Device Number: / /The site executers

Name:

signature:

Date:


39/48


Check list form for installing Medium Voltage Switchgear (to be followed 1/2)


A ( ? ) will be marked for the steps that has been executed and a (X) will be marked for the

other steps.

No The Demonstration Result Instructions Result

1 Switchgears and allsupplements should be

checked upon delivery.

Check up switchgear and all itssupplements at site in

accordance with the drawingsand confirm complete delivery.

2 Install the switchgear uponthe frame and install the

cubicles according to thedrawing.

By Observing and according tothe drawings.

3 Assembling all the

switchgears cubicles andfixing all on the frame

By observing the welding lines

and tighten of the rivets

4 Fixing the sides fiber and

the bushing

By observing

5 Install the cylinder busbarsand the plastic cover aswell.

By observing and making sureof the strength of the tighten bymean of using the momentum

wrench randomly on thebusbars

6 Adjusting the mechanical

movement of the breakeralso adjusting themovement of the moving

portion

By testing the breakers racking

in/out from the cubicles alsochecking the movement of theknob ,the plug ,the gas /oil

indicator and the easymovement of the moving portion

7 Fixing the fiber within the

cubicles

By observing

8 Earthly bit between thecubicles

By observing

9 Gathering and testing the

controls wires according to

each control drawings copy

By observing and running over

all the connections according to

the drawings and testing thecontrols functionality according

to the drawings by feeding thecontrol with external source of

power

10 Install the terminals boxinside the cables then fixingit into the cubicles , also

install down the floors fiber

By confirming the connection ofthe earthly cable with the boxesand the cables nodes , by using

the wrench.


40/48


(followed) Check list form for installing Medium Voltage Switchgear (2/2)


A ( ? ) will be marked for the steps that has been executed and a (X) will be marked for the

other steps.

No The Demonstration Result Instructions Result

11 Fixing up the tools comewith the switchgear

By observing and running overthe measuring devices

indications and the smoothlymovement of the selector

12 Greasing up the moving

mechanical shutter

By observing

13 Testing up the functionality of theswitchgear according to the

requirements14 Checking up the testing

positions of the breakers

15 Checking up the paint and theexternal integrity of the

measuring and visual controldevices

Device name Device Number: / /

The site executers

Name:

Signature:

Date:


41/48


Checklist for installing Main Low Voltage Switchgears


A ( ? ) will be marked upon the steps that has been executed and a (X) will be

marked upon the other steps.

No Tasks required Result Examination Result

1 Switchgear and itssupplements should be

checked up whendelivered from the factory

checkup the Switchgear and all itsaccording to the drawings and

confirm the delivery

2 Installing the board on

the frame according tothe drawings.

By Observing and according to the

drawings.

3 Assemble all the

switchgears cubicles andinstall them on the frame

By observing the welding lines and

tighten the rivets

4 Connecting all the control

wires as in drawings andtest it using external

source.

By observing and reviewing all

connections according to thedrawings, and test the controls

functionality using external source.

5 Connecting the earthingnetwork with the board.

By observing

6 Connecting the cables in

a unified phase.

By reviewing the unification of

phases and assure tightening withthe momentum wrench.

7 Test the functionality ofthe switchgears

components.

Test the functionality of theswitchgears components.

8 Install 3supplements. Observing the supplementsinstallation instructions

9 check the boards devices and

confirm integrity also checkpainting.

10 Test the circuit connection, if

found, by using external source ofpower

Device name . Device Number: / / / 32 / Q /

The site executers

Name: Signature: Date:


42/48


Checklist for installing Iron Frame


A ( ? ) will be marked for the steps that has been executed and a (X) will be marked forthe other steps.

No Tasks required Result Examination Result

1 Confirm the switchgearsdimensions as drawings

Review the boards drawingand match its dimensions with

the frame by using measuringtape

2 Determine the required

amounts of iron beams

3 Adjust the horizontal planof the frame while fixing it

by using a water scale

Check up the horizontal plan ofthe frame by using a water

scale and check up the weldinglines

4 Adjust the horizontal planof the frame from its front

and back among the roomfloor by putting down

softens beneath the frameusing the water scale

Check up the horizontal plan ofthe frame by using a water

scale


The site executersName:

Signature:

Date


43/48


Checklist for installing a Transformer Kiosk


A ( ? ) will be marked for the steps that has been executed and a (X) will be marked for

the other steps.

No

Tasks required Result Examination Result

1 The low and mediumvoltage sides must

be placed in the rightdirection during

unloading

Observe the right direction ofthe low& medium sides

2 Adjust the horizontal planof the kiosk

Use water scale

3 installing the kioskssupplements

By observing and checking it upwith the drawings

4 Test the functionality of

the switches & breakers

Test the functionality of the

switches & breakers

5 Connecting the kiosk withan earthly well

By observing



Signature:..

Date


44/48


Checklist Form for Installing Industrial Earthy Well



the other steps.No Tasks required Result Examination Result

1 (A) Earthy well with the bayonets

dig approximately down 80 cmdepth in clay earth or 125 cm in

deserts

2 Dig down the bayonet till approx20 cm beneath the earth level

3 Cut up the upper part of the

bayonet and make two holes of 11cm2

By observing

4 Build an inspection room up thewell

By observing

5 Connect the well to the required

equipments through wire withsuitable cross section

As the clients requirements and

our offer.

By observing &

matching the wirecross section with theclients requirements &

our offer

6 Measure up and determine theresistance of the earthly well.

By using an ohmmeter

1 B)Earthy well with copper paletteDistinguish the well execution

area with the client and makesure that there are no pipes or

cables buried which will make aconflict with the operation ofdigging down the well

2 Sprinkle water on the well afterdigging it down with suitabledimensions. (2.5-3)m

Device name .Device Number: / / /The site executers

Name:Signature:..

Date


45/48


Checklist Form for Installing an Industrial Earthy Well



the other steps.No Tasks required Result Examination Result

3 Smooth the palette and the copperbar well by using an emery ,then

pierce and join them together.

4 Mix up salt and coal and line up thewell with a 10 cm layer of the

mixture.

5 install the pallet inside the well and

cover it with the rest of the mixture.

6 Put down the iron pipe with the

copper bar inside and fill the well upwith earth till its middle .

By observing

7 Open water on the well then fill upthe rest part with earth till 50 cm

beneath the earth level.

8 Build up the inspection room. By observing

9 Connect the well to the requiredequipments through a wire with

suitable cross sectionAs the clients requirements and our

offer.

Suitable wire crosssection according to

clients requirements &our offer

10Measure up and determine theresistance of the earthly well.

By using an ohmmeter

Device name .Device Number: / / /


Signature:..

Date


46/48


Checklist form when charging the breakers gas for SF6 medium voltagebreakers



the other steps.

No Work steps Cubicle\C.B No.

Cubicle\C.B No.

Cubicle\C.B No.

1 Prepare tools and the cylinder

2 Fix down the gas charging device

on the cylinder and tight it well3 Adjust he gas device according to

the breakers type

4 Blow out air inside the hose

5 Recharge the breaker

6 Close the cylinder

7 Detect any gas leak

Device name .Device Number: / / /The site executers

Name:signature:..

Date


47/48


Check list form when charging the SF6 medium voltage breaker before

charging the switchgear


A ( ? ) will be marked for the steps that has been executed and a (X) will be marked forthe other steps.No Work steps Panel/

C.BNo.

Panel/C.BNo.

Panel/C.BNo.

Panel/C.BNo.

Panel/C.BNo.

Panel/C.BNo.

1 Fix down the moving and fixed

shutters of the withdraw ablebreakers (according to the

tighten values table)

2 Grease the moving shutter ofthe withdraw able breakers to

ease the work

3 Grease the circuit breakers rackin grooves by observation

4 Check up the functionality of thewithdraw able breakers interlock

such that the breaker doesntrack out wile being connected

and not connected if theinterlock is on

5 Check up the smooth movementof the withdraw able breakers

while racking in/out the cubicles

6 There are components and toolswithin the cubicles ( byobserving )

7 Check up the control circuits

according to the drawing.

8 Check up the functionality of thecontrol circuits with an externalsource of power according to the

drawing

9 Check up the electrical interlock

circuits and anti-interfere

10 Carry out the temporary wires

and connections.

Device name ..Device Number: / / /The site executers

Name:Signature:..Date


48/48

ABB Arab

7, Dr. Mohamed kamel HusseinEl Nozha Al Gadida, Cairo, Egypt

Tel.: +20 (2) 6251320Fax: +20 (2) 6222602/03

operational and maintenance instructions manual for medium and low voltage power control & distribut

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