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Operational & Maintenance Instructions Manual For Medium/Low Voltage Power Control & Distribution Switchgears With instructions

for Protection and Limitation of Environmental Pollution

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 powe r distribution and control switchgears.

Part Seven: Simple and tolerable failure for low voltage power distribution and control switchgears and methods of repair . Environmental guidelines digging up for cable laying. Appendices Checklists forms to assure the integrity of the implemented tasks. for clients during

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 the switchgears life span, it would be our pleasure to present you this user guide to preserve high effective performance. This manual contains the best procedures for transporting, installing, operating, performing the maintenance, and fixing up the simple failure of switchgears.

First Part
List of ABB Arabs range of products and a brief about the services offered to clients. Companys Products 1. Medium voltage switchgear and control centers for electrical motors and industrial constructions, and capacitor units up to 36 KV (rated voltage) & up to 50 KA as for the breaking capacity and up to 4000 Amp. feeding current provided with vacuums and SF6 vacuums contactors , and fixed or withdrawable circuit breakers. Low voltage switchgear and control centers industrial constructions, and capacitor units up Amp. feeding current and up to 100 KA for the with MCB or MCCB or ACB motor starters withdrawable or fixed fuse starters. for electrical motors and to 1000 V and up to 5500 breaking capacity provided or circuit breakers, fuses,

2.

3.

Designing and production for any medium or low voltage cubicles e.g. the extension switchgears and control centers or upon customer request. Providing solutions for retrofitting the medium voltage switchgears. Sub-distribution switchboards. Consumer units or flat boxes. Compact sub -stations (transformer kiosk) for out-door use up to 24 KV and 2000 KV Amp. Medium & Low Voltage Cable trays. Standard products ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? Medium and low voltage circuit b reakers. Medium and low voltage current transformers. Potential transformers up to 24 KV. MCCB up to 1250 A. MCB up to 63 A. 10 or 15 A. up to 4 poles. Medium voltage fuses up to 24 KV. Low voltage fuses. Medium and low voltage circuit Isolators made from Epoxy rating, araldite or from porcelain

4. 5. 6. 7.

8. 9.

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ABB Arab customer service center offers the following services. 1. 2. 3. 4. 5. 6. Installing all switchgears and all their supplements of cables, transformers supplied and produced by ABB Arab. Supervising the switchgears installation, supplied and produced by ABB Arab. Offering recommendations to supply the suitable spare parts for all types of switchgears produced by ABB Arab. Offering the protective maintenance for switchgear. fixing up switchgears in case of failure. Taking the required measurements to improve the power factor and measuring the ranks of the loads harmonious and recommending solutions to remove these harmonious. Performing the measurements among the pre-established paths.

7.

Quality Policy We, all ABB Arab manpower are one team, our main aim is to execute all the internal 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 firms manpower. Sticking to all what have been stated in the Egyptian laws concerning the environment preservation. The continuous preceding of improving and eliminating the environmental polluters. Rationalizing the use of natural resources.

2. 3. 4.

All of which would be verified through the following: ?? Establishing, applying and performing the required maintenance for the environmental management syste m according to the international environmental standards ISO 14001. Performing the international evaluation on the main and subsidiary goals of 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 the products 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 the switchgear). 2- Fixing up the switchgears on the truck with appropriate fixing means which 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 adjusted on a (jeg) inside the plant and any crookedness or bending happen to these 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 the switchgears weights. Secondly: Storing the switchgears Sometimes there is a long duration between the delivery time and the installation, 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 the operation). 4. After installing the switchgear in the site, all the cables outlets beneath the switchgear must be sealed off, especially in the desert site. ABB Arab Operation & Maintenance Manual 6/48

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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1Site Inspection:

Installing a Ring Main Unit

? ? The site must be fully inspected and the rooms dimensions must be taken to fit the units dimensions and the cable trays beneath the unit and the entire 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 or prevents 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 and checking the existence of power resource there. ? ? The tools like the meter , angle , the fork should be used to mold iron according to the required measurements. ? ? All the iron beams and angles will be cut after marking them up using the cutting disk. ? ? All the iron beams and angles should be welded after adjusting upon one internal 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 cone afterward 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 directions thus 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 6 cement 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 for installing the unit. Installing the unit The one who is in charge for performing the tasks should fill checklist form for installing a new Ring Main Unit. At the site, People who are in charge should receive and bring the unit in by 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 thermo plastic 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. 2. 3. 4. 5. 6. 7. 8. 9. Fixing the unit on its pre-designed frame, by going over the welds or the rivets. All the tightens must be tightly closed with the moment wrenches. Connecting the ring core which belongs to the earth failure indicator device. The functionality of the load break switches with a suitable tool. Connecting the unit with the main earthen network The straps of the controls wires and heaters must be well tighten if found . The fixing of the units bottom covers after installing the cables. The connections of current transformer, voltage transformer, voltmeter & ammeter and all available measurements devices. 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 checklist form for medium voltage switchgear installation. ? ? At the site, People who are in charge should receive and place in the switchgear 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 the single line diagram and mechanically assembling its cubicles by the bolts while making sure that it is vertically and horizontally balanced upon all its corners. ? ? 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 prevent the 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 be able 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 form should 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. 2. 3. Adjusting the board balance vertically and horizontally. Fixing the board on the iron frame. 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, MCB and 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. 12. 13. 14. 15.

Check the C.Bs mechanical & electrical performance. Check The gas pressures or oil level in the C.Bs according to its type. Fixing and tightening the power cables in the switchgear. Check functionally the electrical interlock using an external power source. All data of M.V C.Bs periodical maintenance checklist form should be filled, 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 or damaging 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 d rawings and numbering. The switchboards control should be tested assuring the electrical interlock between 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 list form 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 the coating. 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 an external power source All data for MV cubicles & C.Bs periodical maintenance chick list form should 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 be signed like (receipting acknowledge , current flow ) for all what have been settled 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 the transformer 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.

6Tools used:

Installing a Terminal Box for a Medium Voltage Cable

Measuring tape a saw- welding gas cylinder fully cable hydraulic press with lugs emery- weld caustic handkerchief (for cleaning) a file cable rasp Installing Procedures: The one who is in charge for performing the tasks should fill LV terminal box installation & testing check list form. The box used should be suitable for the cable for both dimensions and voltage, also it must be according to the standards ( by the sticker tipped on the box and checking up precisely the installation catalogue) also hands must 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 out by pair of tongs. Remove the internal cover of the cable by peel knife to find the phases are rolled 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 copper start end. The black case should be heated with welding gun and the flame should be adjusted 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 cable over/above the shield. The tri-box should be installed in the cable till the end of the phases then it should 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 from its beginning The rubber tape should be starched such that its new width must be half its original one, then it should be rolled on the terminals such to be put half upon half The long red case should be set on the cable and weld with the gun just as the later After the case has been shrunk , it must been checked up for making sure that 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 cable lifting up method (if necessary) Installing Procedures: The cables measurement will be taken with the tape The required measure will be cut off b y 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 grater then or equal 6 times of the cables diameter An adequate terminal should be used for the conductors sector and type and 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 testing model lists for installing a terrestrial industrial well. (A) Earthing well 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 wrench 17 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 demands 2-3 copper terminal according to the required length of the cable 2-4 rivets 10X40mm 2-5 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 advance so that it will never conflicts with the streets , underground pipes or buried cable paths and it would rather be near a continuous water resource. clay earth must be dug for 80 cm and 125 cm for deserted one before start hammering the bayonet the bayonet will be hammered till it reaches 20 cm under the earth level the pit then will be refilled up with earth till 50 cm under the earth level the bayonets edges should be cut with the saw the bayonets surface must be drilled to make 2 holes with diameter 11mm the floor must be lined with a concrete layer of 10mm thickness 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 it the cover of the examination room which is made of cast iron will be fixed 3cm above earth the ground wires will be lined and fixed on the bayonet after attaching its ends with copper terminals the resistance of the terrestrial well must be measured and defining the real value of the well resistance

3-2 3-3 3-4 3-5 3-6 3-7 3-8 3-9 3-10 3-11

(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 wrench 17 cable hydraulic press with lugs- measuring tape- pair of tongs- wire ripper 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 works requirements. 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. ABB Arab Operation & Maintenance Manual 17/48

33-1

Work Procedures: 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 continuous water resource. Ordinary employment would be hired to dig the well of dimensions 1.5X1.5X2.5 meter for soft earth and 2X2X3 for tough earth The well should be well sprinkled with water 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 edge 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 other side 5 holes with 4 cm between each and other with the first at 2cm form the edge The emery must be used well on both the palette and the frond The palette and the frond will be liked together by using the rivets 10X40mm with all their parts 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 The palette and the frond will be put over the mixer then another layer of the mixer will be put over them The stainless steel tube must be fixed on the copper frond at the bottom of the well and even before the earth level with about 35 Cm 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 with earth till 50 cm beneath the earth surface Concrete must be poured over the well with thickness of 10 cm then the examination room will be built with dimensions of 50X50 cm and height of 35 cm then lining it from in and out, and making holes in it for letting the wires get out from it The cover of the examination room which is made of cast iron will be fixed 3cm above earth and will be fixed with concrete The ground wires will be lined and fixed on the bayonet after attaching its ends with copper terminals The resistance of the terrestrial well must be measured and defining the real value of the well resistance

3-2 3-3 3-4

3-5

3-6 3-7 3-8 3-9 3-10 3-11

3-12

3-13 3-14 3-15

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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 preparing alkali solution


1- The required amounts of salts to a set of batteries 100 Amp. /hour Amount 45 4 115 Unit Kg Kg liter Description Potassium hydroxide Lithium hydroxide Distilled Water

2- Tools required to form the solution 2-1 Hydrometer 2-2 A plastic container 2-3 A plastic cone 2-4 Pair of plastic gloves for skin protection 2-5 Clean plastic or wooden stick 2-6 A plastic jar 20 liter of distilled water. 2-7 2 metallic poles. ABB Arab Operation & Maintenance Manual 19/48

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 be 1.19+.002 at 20? C. 2-20 Density can be adjusted by adding little amount of salt or distilled water 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 checked 2-22 The battery will be filled till its upper limit 2-23 The battery will then be connected to the charger and will be charged till 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 the two 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 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Type & kind of the tool Set of ordinary wrenches Set of toothed wrenches Set of Alan wrenches Set of Alan wrenchs bits Set of revolvers bits Set of screwdrivers Set of large props Straight pliers Flexed pliers Straight pliers Internal opening pliers Doggy pliers Goosed head straight pliers Backed foot Measuring filler Measuring meter Set of multiple files French wrench Smith hammer Plastic hammer Estensal wrench Tighten hand for bits Tighten hand joint Full set of short bits Small water scale Set of bonds Set of gathe ring the tulip contact Q 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 3 2 2 1 1 1 2 1 1 20 Different sizes Special Set Long and short Full Set 12 5 meters long 10,6 , 1/5 Kg Notes 12 pieces (6:32 mm) 12 pieces (6:32 mm) 12 pieces (2 :17 mm) 7 pieces (4:17 mm) 6 pieces (8 :19) 5 pieces-different sizes 7 pieces (5:10) 8,6 8,6 6 6

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Contents of a consummate toolbox for a (electrical) technician No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Type and kind of the tool Set of ordinary wrenches Set of toothed wrenches Set of Alan Keys Set of Alan Keys bits Set of revolvers bits Set of screwdrivers Voltammeter Sanding box ( collection ) Wires peeler Ordinary straight pliers Wire shatter Sanding Piston (presser ) Measuring tape 5 meters Smith hammer Plastic hammer Tighten hand for bits Tighten hand joint Full set of short bits Q 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 2 1 Short and long Small , 1/5 Kg Notes 12 pieces (6:32 mm) 12 pieces (6:32 mm) 12 pieces (2 :17 mm) 7 pieces (4:17 mm) 6 pieces (8 :19) 5 pieces-different sizes For measuring the volt

Commonly used tools 1- Air blower 2- Electrical driller

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Contents of a consummate toolbox for installing technician No Type and kind of the tool 1 Tool bag 2 Small test wrench 3 Big test wrench 4 Water scale 30cm 5 Saw frame 6 Set of pipes 7 Concrete liner 8 Set of ordinary wrenches 9 Set of short Alan 10 Set of large Alan 11 Alan wrench 12 French wrench 13 Reversible sparks spectacles 14 Welder 15 Isolated nipper 16 Isolated shatter 17 Methyl pliers 18 Hammer 19 Smith hammer 20 Smith hammer 21 Concrete breaker bond 22 Bricks breaker 23 Isolated Wires peeler 24 Marking angle 25 Set of mouse tail filers 26 Set of flatted filers 27 Set of semi-sphere filers 28 Large crossed screwdriver 29 Large ordinary screwdriver 30 Set of props 31 Opening pliers 32 Tighten pliers 33 Measuring tape 34 Set of toothed wrenches 35 Set of ordinary wrenches 36 Sanding pliers 37 Doggy pliers 38 Estensal wrench Commonly installing used tools 1- inner terminal cable press 2- air blower 3- electrical driller 4- cable scissors ABB Arab Operation & Maintenance Manual Q 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Notes

German English 3pieces (13:19mm) Small 8 pieces 10 pieces (2:12 mm) 10 pieces (2:12 mm) 17 mm 12 0.75 Kg 8 6 10 1.5 kg 0.5 kg .025 kg 12 12

3 pieces (6:8:10) 3 pieces (6:8:10) 3 pieces (6:8:10) Full iron square Full iron square 12 pieces 7 7 5 meters 12 pieces 12 pieces 10 12

5- welding trance 6- welding trance 7- cutting disc 8- rocket 23/48

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 box 2- Air blower 3- Cleaning forms 4- Greases 5- Medium volt test stick 6- Special tool for cables tighten 7- Prams out hands for all types of breakers B- Following the safety rules: Before starting any cubicles maintenance the following instructions should be followed: 1. 2. 3. 4. 5. 6. 7. Putting on the safety helmet and wearing the safety shoes Cutting off the power Making sure that nobody else can put on the power Testing ins and outs cables to make sure that there is no voltage Connecting the bar with the earthly Covering the equipments which may conduct electricity during the maintenance It should be confirmed that all the power is off and there us no voltage from any power resource and this is by testing with the testing stick (the tower) and after making sure of the earthly status whether it was a switch or tighten set.

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C- How to do a periodical maintenance of the cubicles All the breakers should be brought out from the cubicles ,and then all the power cables should be measured such to make sure that there is no return back current , then the following must be done : 123456Separating the fixed and moving shutter cleaning up the busbar room and supports using the air blower Cleaning up the busbars upper flower box Cleaning up the busbars lower holder Cleaning up the current and voltage transformers according to each cubicles function 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 table rejoining the busbars support with the busbars upper flower box according to the tights values table Rejoining the fixed contact of the cubicle l (the busbars upper flower box) Rejoining the current transformers according to the tights values table reconnecting the connections of the current transformer control Rejoining the current transformer with the busbars flower box according to the tights values table Rejoining the current transformer with the cable flower box cupper according to the tights values table Rejoining the busbars lower holder according to the tights values table Rejoining the fixed contact of the cubicle (the busbars lower holder) according to the tights values table making sure of making earthly switch and how to plug them on and off running over the connection of the heaters with the cubicles (of found) Running over the connection of the earthly with the cubicles according to the tights values table Running over the connection of the side lock of the breaker among the two sides of the cubicle Running over the connection ring upon the breaker and making sure that it is valid and contains no crooks Cleaning up the cubicles control room and running over the control connection within the cubicles control room Making sure that all the equipments of the control room technically run properly (MCB key-timer-contactors relays, ..) Reconnecting the wires with the roses making sure that the wires are lying in their paths and they are covered.

891011121314151617181920 21222324-

ABB Arab Operation & Maintenance Manual 25/48

D- How to do a periodical maintenance to breakers 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Separating the breakers front door Making a comprehensive cleaning for all the barkers Checking up the oil level or gas pressure according to the kind of the breaker Performing the maintenance on the mechanical group ( cleaning greasing oiling ) Adjusting the interspaces of the mechanical group according to the technical catalogues Running over the functionality of the moving parts within the mechanical group Testing the files of plugging , unplugging ,plugging hindrances and the breaker at the testing mood Testing up the breakers motor Testing up the functionality of the mechanical aids points of the breaker Testing up the functionality of plugging and unplugging the breaker Testing up the in and out position of breakers from/to the cubicle Final testing of the breaker within the cubicle to adjust the mechanical interlock of the breaker Testing up the functionality of control circuit while having the breaker on operating mood within the cubicle All the tighten points should be left up from the cubicles or unplugging the earthly switches Putting all the breakers within the cubicles such that all the entering and joining breakers will be right placed Making sure that there is no tools on the cubicle or the breaker such to avoid a short circuit The site should be admitted to the engineer on charge and power should be flowed fort the entering breakers If the clients demanded to flow the power on the exiting breakers ,this will happened among his occurrence and supervision All the tasks which have been performed should be signed up in a delivery form such that all the work done with the client would be maintained.

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Fifth Part
1 Medium Voltage Cubicles Common failure and how to fix
Failure Description
1 ??The breaker doesnt accept The breaker doesnt to be switched on via the push button on the devices door ( the breaker could be temporary operated through the connecting push button in the breakers front part)

Reasons of the Failure


??Disconnect the cubicle control via the MCB in the measurements compartment. ??No voltage on the operating coil ??Damage in the operating coil ??Socket & plug are not well connected ?? Disconnect of the cubicles control through the MCB ?? damage of the disconnection coil
?? horizontal

Way of Detection
??External check-up ??Measure the operating applied voltage ob the operation coil. ??External check-up (inflation in the coil) ??Check through the hole beneath the device room
?? General

Way of Fixing
??Connect the cubicles control via the MCB in measuring compartment ??Check the cubicles control ??Change the operating coil ??Connect well the plug with the socket.

The breaker doesnt shut off via the push button ( the breaker can be temporally operated via the push button on front ) The breaker racks hardly in the cubicle

check up ?? General checkup (inflation in the coil)


?? Adjust

?? Connect

of the cubicles control through the MCB ?? Replace the disconnecting coil
?? Adjust

No volt on the control circuits though there is on the cables

& vertical plans of the cubicles are not adjusted ?? the damage on the panels moving wheel due to bad ground floor ?? The Potential transformers fuses are not well plugged

the horizontal & vertical plans of the cubicles by a water scale ?? General check up
?? General

the floor and re-fix the switchgear on an iron frame

?? Change

check up

the wheel and adjust the ground floor ?? Plug the Potential transformers fuses

ABB Arab Operation & Maintenance Manual

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2 Medium Voltage Cubicles Common Failure and How to Fix


No
5

Failure description
?? The

Reasons of the failure


??There

Way of detection
Making sure of: ??Fully isolate the transformers oil ?? integrity of the transformers coil ?? Adjust values for overload / short circuit relay. ??Integrity of cable between the transformer and the cubicle ?? Relays values for voltage raise / fall
?? Charge ?? Refine ?? Fix

Way of fixing
the transformers oil.

breaker is in trip position when connected

is a rush current within the transformer.

the transformer coils. the relay. the cable.

?? Adjust

??Damage

in cable between the transformers and the cubicle of the protection relay

?? Replace

?? Disconnection

?? Adjust

the raise/fall voltage relay it

The breaker doesnt operate via the push button + hearing a tone

?? The

breakers spring is not charged in the anti connection

?? Damage

motors breaker is disconnected ?? Dust covers the chargeend switch ?? Inflation in the coil
?? It

?? Connect ?? Clean

the switch from dust. the anti-plugging coil

?? Replace ?? Grease

coil
?? The

The breaker works for a while then disconnect

moving knob is not in right position. ?? The values of the relays are not proportionally adjusted CTs & loads values

must be moved clock wisely to its path. ?? Read & record the relay sitting values

the groove of the moving knob ?? Adjust the relay proportionally with value of load current & the transformers fixed on the cubicles

ABB Arab Operation & Maintenance Manual

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3 Medium Voltage Cubicles Common Failure and How to Fix


No
8

Failure Description
The ATS doesnt work properly

Reasons of the Failure


?? Timers

Way of Detection
?? Read

Way of Fixing
?? Adjust

are adjusted for short time durations , thus time values must be longer then time needs to recharge the breakers motor. sure of connecting the moving and the fixed plugs in the cubicle.

the timers values

the timer to 10 seconds.

?? Make

??Damage

Hearing sound within the cubicles

in one of the circuits components ??Dust on surface ??Humidity in the cubicles

down the moving and fixed plugs before the breaker racks into the cubicle. ?? Call ABB ARAB service center

?? Push

?? Push

down the moving and fixed plugs before the breaker racks into the cubicle. ABB ARAB service center

?? Call

?? Clean

the surfaces sure about adjusting the hygrostats values. ?? Confirm connecting and operating heaters.
??Make ??Confirm

10

Hotness within the cubicles

??Loosens

of the contact joints on the main & sub busbar.

that values of all connections in cubicles are according to the momentum values in the manual.

ABB Arab Operation & Maintenance Manual

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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 breaker should 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 nodes might 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 functionality 2- Tools that are oriented for maintenance ? ? A complete tool box ? ? Air blower ? ? Cleaning forms ? ? Greases ? ? testing stick ? ? Special tool for cables tighten 3- Cleaning Equipments ? ? Air source for vacuuming or blower ? ? Cloth ( soft not fabric not synthetic not colored no reuse for the unclean cloth) ? ? Detergent (Tricolor Ethan carob tetra chloride ) for moving down greases , oils and charcoal from the connecting and anti-rusting surfaces Note: Neither petroleum nor alcoholic based materials should be used in cleaning Joining up table Joining tools Rivet 8mm Rivet 10mm Rivet 12mm Rivet 16mm ABB Arab Operation & Maintenance Manual Joining values 15 Newton meter 30 Newton meter 60 Newton meter 120 Newton meter 30/48

4-Cubicles Maintenance Steps of performing the cleaning up: 1234The current should be disconnecting before starting cleaning up Using the air blower to cleaning the pass bar Cleaning up the low voltage isolators which carry the pass bar Cleaning up the whole cubicle

Steps of tighten up: 1234The values in the table will be used to tighten up by using the momentum wrench according to the Joining up tables values Retighten the pass bars parts by using the Joining up tables values Rejoining the fixed contact in the cubicle according to the Joining up tables values Rejoining the controls wires

Steps of testing up the functionality: By running over the following: 1. 2. 3. 4. 5. The mechanical movement of the cubicles parts The control connections in the cubicles All the parts are working properly ( MCB key contact warts- timer relays) The tighten of the wires with the rosettes 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 Normal Maintenance program Performing an external check then cleaning up the dust The same maintenance program as the next clause Duration Once per year at least

Breakers are working in dusty climate ,high % of humidity, & temp. and vibrate during operating After a shortage takes place on the breaker

Once per six months at least

Check the main contact & Before putting the the sparking room as breaker on operation stated in the next clause another time 31/48

ABB Arab Operation & Maintenance Manual

Details of performing general maintenance on the breakers parts No 1 The part requires Checking up result maintenance - The breakers o uter - Existing of dust and body dirt on the breaker Method of performing the maintenance - Blowing out the dust by using the air blower and the dirt by using a clean and dry piece of cloth - Tighten up with a momentum wrench - Removing the oxidizing with a very fine emery

- Connecting nodes between the breakers and the joints ( brass cables) -The breakers mechanism

- Rivets and nuts are not well tighten - The nodes are oxidized

- A resistance in the - The breakers face must operation of be separated and connecting and cleaned up and greasing disconnecting the the mechanical group breaker - The breakers main - Covered with dust and - The contact surface must contact dirt be cleaned with fine material (fine emery) - The outer body of the - There are zigzags on - It must be replaced sparking extinguishment the rooms surface room -The metal part of the - Covered with dust - Blowing out the dust from sparking extinguishment it by using the air blower room

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 is synthetic 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.

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Different Failure For Low Voltage Air Breakers and Methods For Fixing.
Expected Failure Breaker doesnt accept to be plugged on Breaker doesnt accept to be disconnected Breaker makes a contentious disconnecting An over heat on the connections An over heat on the main contact The mechanical auxiliary contact doesnt perform well Ways of checking up Ways of fixing up the the failure failure There is no voltage There is no voltage sources sources on the terminals on the terminals of the of the voltage falls coil voltage falls coil checking up the voltage source removing out the voltage resource

Failure probabilities There is no voltage sources on the terminals of the voltage falls coil There is voltage sources on the terminals of the voltage falls coil Plugging coil doesnt perform well The thermal relay was disconnected since a short while Failure in the breakers mechanism Disconnecting coil is not performing well Over heating on the main contact The relay is not well adjusted thermal relay is not appropriate with the loads Over heating on the connections Over heating on the main contact of the breaker Wrong connecting for the mechanical auxiliary contact Over heating on the main contact of the breaker

checking up the coils movement .

Cleaning up and removing obstacles Replacing the coil if spoiled wait few minutes then try plugging again Call ABB Arab service center Cleaning up and removing obstacles Replacing the coil if spoiled Making sure that the tightening is according to the momentum values. well adjusting the relay with respect to the load well adjusting the relay with respect to the load Making sure that the tightening is according to the momentum values. Making sure that the tightening is according to the momentum values. Rechecking the connections according to the design of the control. Retighten the wires Making sure that the tightening is according to the momentum values.

* * * * * * * * * * *

..

Rechecking the coil movement .

Measuring the real loads Measuring the real loads

..

The automatic circuit doesnt work (if found) Signs lamps dont work

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Different Failure For Low Voltage Air Breakers and Methods For Fixing.
Expected Failure Breaker doesnt accept to be plugged on Breaker doesnt accept to be disconnected Breaker makes a contentious disconnecting An over heat on the connections An over heat on the main contact The mechanical auxiliary contact doesnt perform well Ways of checking up Ways of fixing up the the failure failure There is no voltage There is no voltage sources sources on the terminals on the terminals of the of the voltage falls coil voltage falls coil checking up the voltage source removing out the voltage resource

Failure probabilities There is no voltage sources on the terminals of the voltage falls coil There is voltage sources on the terminals of the voltage falls coil Plugging coil doesnt perform well The thermal relay was disconnected since a short while Failure in the breakers mechanism Disconnecting coil is not performing well Over heating on the main contact The relay is not well adjusted thermal relay is not appropriate with the loads Over heating on the connections Over heating on the main contact of the breaker Wrong connecting for the mechanical auxiliary contact Over heating on the main contact of the breaker

checking up the coils movement .

Cleaning up and removing obstacles Replacing the coil if spoiled wait few minutes then try plugging again Call ABB Arab service center Cleaning up and removing obstacles Replacing the coil if spoiled Making sure that the tightening is according to the momentum values. well adjusting the relay with respect to the load well adjusting the relay with respect to the load Making sure that the tightening is according to the momentum values. Making sure that the tightening is according to the momentum values. Rechecking the connections according to the design of the control. Retighten the wires Making sure that the tightening is according to the momentum values.

* * * * * * * * * * *

..

Rechecking the coil movement .

Measuring the real loads Measuring the real loads

..

The automatic circuit doesnt work (if found) Signs lamps dont work

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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 Normal Maintenance program Performing an external check then cleaning up the dust Same maintenance program as the next clause Duration Once per year at least

Contractors work in dusty climate, high % of humidity & high temp. and vibrate during operating

Once per six months at least

Details of performing general maintenance on contactors parts S 1 Part requires Checking up result maintenance the contactors outer -existing of dust and dirt body on the contactor Maintenance methods

blowing out the dust by using the air blower and the dirt by using a clean and dry piece of cloth Connecting nodes Rivets and nuts are not Tighten up with a between the contactor well tighten momentum wrench and the joints ( brass The nodes are oxidized Removing the oxidizing with cables) a very fine emery The contactors main Covered with dust and dirt contact The contact surface must be cleaned with fine material (fine emery)

ABB Arab Operation & Maintenance Manual 35/48

Expected failure, reasons and ways of fix ing, for power factor correction Units No 1 Failure description The regulator doesnt output units though there are loads on the boards Reasons of occurring Way of fixing

The power factor doesnt reach the device adjusted value

The regulator signs that there are units at service but the contactors are in OFF position

All units at service and the power factor is still low

- Blown up of the fuses ( or disconnecting the breakers ) which are placed on the capacitors units drawers. - High ring tone on the main breaker of the Capacitor banks - Capacitors burning up

-Wrong connection. - Check the device in the -Wrong in adjusting the automatic position. C/K values. - Confirm connecting the C.T e.g. C.T is on the R position and the voltages terminals are on S&T position. - Low calculated current to - Adjust the C/K value. be distinguished by the - Recheck the C.T % & the device. This value is value of the real defined for every device calculated current in the catalogue. - Adjust the time duration just before operating. - Wait for adjusted the time duration Very low power factor in - Fixing some capacitors for spite of high rated no load situation. capacitors and very low - Reduce the set rated load current. capacity (50KVAR~25KVAR) - Wrong connection Check contactors connections - Wrong connection - Check regulator outlets. between the C.T and the - Total loads ( load current electronic regulator + capacitors current ) should pass within current transformer Wrong C.T installation -Make sure that C.T installation is in the right position according to the No fuses are available or drawings. fuses are blown up. -Replace the damaged fuses -There are load - Filters must be installed to harmonics. prevent the effect of these -(High distortion in the sine harmonious. wave of the current and the voltage)

ABB Arab Operation & Maintenance Manual 36/48

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 the plugging 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 your manpower: 1. All the diggers must be announced to wear safety shoes, dust protector, eyes protector, head caps for sun protection and of course these must be available for their use 2. It must be made sure of ( from a specialized authority ) that the digging path is free 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 authority should 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 collecting areas while stressing on not polluting environment and roads while transmitting 5. ABB ARAB is sharing you the serious pursuing to preserve all the environments elements and we are honored to inform you that we have a strong 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

ABB Arab Operation & Maintenance Manual 37/48

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 for the other steps. Tasks required 1 Adjust setting 0 level for R.M.U 2 Fix up the R.M.U on the frame 3 Connect earth failure indicator & its C.T. 4 Install all supplements supplied with the R.M.U Function test of the R.M.Us components by plugging and unplugging the switches Result Examination Using a water scale General check for the line wildings and the buts. Check up the connections By observing Check the integrity of the mechanism and precise contact connection. / / Result

Device name .Device Number: The site executers Name: signature: Date:

ABB Arab Operation & Maintenance Manual 38/48

Check list form for installing Medium Voltage Switchgear (to be followed 1/2) Clients name .. File number ...

A ( ? ) will be marked for the steps that has been executed and a (X) will be marked for the other steps. No 1 The Demonstration Switchgears and supplements should checked upon delivery. all be Result Instructions Check up switchgear and all its supplements at site in accordance with the drawings and confirm complete delivery. By Observing and according to the drawings. Result

4 5

Install the switchgear upon the frame and install the cubicles according to the drawing. Assembling all the switchgears cubicles and fixing all on the frame Fixing the sides fiber and the bushing Install the cylinder busbars and the plastic cover as well.

By observing the welding lines and tighten of the rivets By observing By observing and making sure of the strength of the tighten by mean of using the momentum wrench randomly on the busbars By testing the breakers racking in/out from the cubicles also checking the movement of the knob ,the plug ,the gas /oil indicator and the easy movement of the moving portion By observing By observing By observing and running over all the connections according to the drawings and testing the controls functionality according to the drawings by feeding the control with external source of power By confirming the connection of the earthly cable with the boxes and the cables nodes , by using the wrench. 39/48

Adjusting the mechanical movement of the breaker also adjusting the movement of the moving portion Fixing the fiber within the cubicles Earthly bit between the cubicles Gathering and testing the controls wires according to each control drawings copy

7 8 9

10

Install the terminals box inside the cables then fixing it into the cubicles , also install down the floors fiber ABB Arab Operation & Maintenance Manual

(followed) Check list form for installing Medium Voltage Switchgear (2/2) Clients name .. File number ...

A ( ? ) will be marked for the steps that has been executed and a (X) will be marked for the other steps. No 11 The Demonstration Fixing up the tools come with the switchgear Result Instructions By observing and running over the measuring devices indications and the smoothly movement of the selector By observing Testing up the functionality of the switchgear according to the requirements Checking up the testing positions of the breakers Checking up the paint and the external integrity of the measuring and visual control devices / / Result

12 13

Greasing up the moving mechanical shutter

14 15

Device name Device Number: The site executers Name: Signature: Date:

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Checklist for installing Main Low Voltage Switchgears Clients name .. File number ...

A ( ? ) will be marked upon the steps that has been executed and a (X) will be marked upon the other steps. No 1 Tasks required Switchgear and its supplements should be checked up when delivered from the factory Installing the board on the frame according to the drawings. Assemble all the switchgears cubicles and install them on the frame Connecting all the control wires as in drawings and test it using external source. Connecting the earthing network with the board. Connecting the cables in a unified phase. Test the functionality of the switchgears components. Install 3supplements. Result Examination checkup the Switchgear and all its according to the drawings and confirm the delivery By Observing and according to the drawings. By observing the welding lines and tighten the rivets By observing and reviewing all connections according to the drawings, and test the controls functionality using external source. By observing By reviewing the unification of phases and assure tightening with the momentum wrench. Test the functionality of the switchgears components. Observing the supplements installation instructions check the boards devices and confirm integrity also check painting. Test the circuit connection, if found, by using external source of power Result

5 6

8 9

10

Device name . Device Number: The site executers Name:

/ 32 / Q /

Signature:

Date:

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Checklist for installing Iron Frame Clients name .. File number ...

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

No 1

Tasks required Confirm the switchgears dimensions as drawings

Result

Examination Review the boards drawing and match its dimensions with the frame by using measuring tape

Result

Determine the required amounts of iron beams

Adjust the horizontal plan of the frame while fixing it by using a water scale Adjust the horizontal plan of the frame from its front and back among the room floor by putting down softens beneath the frame using the water scale

Check up the horizontal plan of the frame by using a water scale and check up the welding lines Check up the horizontal plan of the frame by using a water scale

Device name . The site executers Name: Signature: Date

Device Number:

/ 32 / Q /

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Checklist for installing a Transformer Kiosk Clients name .. File number ...

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

No Tasks required 1 The low and medium voltage sides must be placed in the right direction during unloading Adjust the horizontal plan of the kiosk installing the kiosks supplements Test the functionality of the switches & breakers Connecting the kiosk with an earthly well Result Examination Observe the right direction of the low& medium sides Result

Use water scale

3 4 5

By observing and checking it up with the drawings Test the functionality of the switches & breakers By observing

Device name . The site executers Name: Signature:.. Date

Device Number:

/ 32 / Q /

ABB Arab Operation & Maintenance Manual 43/48

Checklist Form for Installing Industrial Earthy Well Clients name .. File number ...

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 (A) Earthy well with the bayonets 1 dig approximately down 80 cm depth in clay earth or 125 cm in deserts 2 Dig down the bayonet till approx 20 cm beneath the earth level 3 Cut up the upper part of the By observing bayonet and make two holes of 11 cm2 4 Build an inspection room up the By observing well 5 Connect the well to the required equipments through wire with suitable cross section As the clients requirements and our offer. Measure up and determine the resistance of the earthly well. B)Earthy well with copper palette Distinguish the well execution area with the client and make sure that there are no pipes or cables buried which will make a conflict with the operation of digging down the well Sprinkle water on the well after digging it down with suitable dimensions. (2.5-3)m / / / By observing & matching the wire cross section with the clients requirements & our offer By using an ohmmeter

Device name .Device Number: The site executers Name: Signature:.. Date

ABB Arab Operation & Maintenance Manual 44/48

Checklist Form for Installing an Industrial Earthy Well Clients name .. File number ... 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 3 Smooth the palette and the copper bar well by using an emery ,then pierce and join them together. Mix up salt and coal and line up the well with a 10 cm la yer of the mixture. install the pallet inside the well and cover it with the rest of the mixture. Put down the iron pipe with the copper bar inside and fill the well up with earth till its middle . Open water on the well then fill up the rest part with earth till 50 cm beneath the earth level. Build up the inspection room. Connect the well to the required equipments through a wire with suitable cross section As the clients requirements and our offer. Measure up and determine the resistance of the earthly well. / / / By observing

5 6

8 9

By observing Suitable wire cross section according to clients requirements & our offer By using an ohmmeter

10

Device name .Device Number: The site executers Name: Signature:.. Date

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Checklist form when charging the breakers gas for SF6 medium voltage breakers Clients name .. File number ...

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

No 1 2 3 4 5 6 7

Work steps Prepare tools and the cylinder Fix down the gas charging device on the cylinder and tight it well Adjust he gas device according to the breakers type Blow out air inside the hose Recharge the breaker Close the cylinder Detect any gas leak

Cubicle\ C.B No.

Cubicle\ C.B No.

Cubicle\ C.B No.

Device name .Device Number: The site executers Name: signature:.. Date

ABB Arab Operation & Maintenance Manual 46/48

Check list form when charging the SF6 medium voltage breaker before charging the switchgear Clients name .. File number ... A ( ? ) will be marked for the steps that has been executed and a (X) will be marked for the other steps. Panel/ Panel/ Panel/ Panel/ Panel/ Panel/ No Work steps C.B C.B C.B C.B C.B C.B
No. No. No. No. No. No.

3 4

7 8

Fix down the moving and fixed shutters of the withdraw able breakers (according to the tighten values table) Grease the moving shutter of the withdraw able breakers to ease the work Grease the circuit breakers rack in grooves by observation Check up the functionality of the withdraw able breakers interlock such that the breaker doesnt rack out wile being connected and not connected if the interlock is on Check up the smooth movement of the withdraw able breakers while racking in/out the cubicles There are components and tools within the cubicles ( by observing ) Check up the control circuits according to the drawing. Check up the functionality of the control circuits with an external source of power according to the drawing Check up the electrical interlock circuits and anti-interfere

Carry out the temporary wires and connections. Device name ..Device Number: The site executers Name: Signature:.. Date ABB Arab Operation & Maintenance Manual

10

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ABB Arab 7, Dr. Mohamed kamel Hussein El Nozha Al Gadida, Cairo, Egypt Tel.: +20 (2) 6251320 Fax: +20 (2) 6222602/03 E- mail: abbarab@eg.abb.com www.abb.com/eg