ABB SAHARA Series User manual

PTMV - Medium Voltage Equipment
ABB Electrical Industries Co. Ltd.
Kingdom of Saudi Arabia
ABB
SAHARA Series
Compact Substation
OPERATING INSTRUCTIONS
MODELS:
24kV 36kV
SAHARA 500 SAHARA MAX-1
SAHARA 1000 SAHARA MAX-2
SAHARA 1600
SAHARA 2000
SAHARA 3000

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Table of Contents
INTRODUCTION.................................................................................................................................... 3
GENERAL................................................................................................................................................3
RECEIVING/INSPECTION/STORAGE ..............................................................................................4
PERSONNEL SAFETY ..........................................................................................................................4
VENTILATION .......................................................................................................................................4
EARTHING..............................................................................................................................................4
HANDLING .............................................................................................................................................4
SAFETY NOTES FOR OPERATIONS ................................................................................................5
INSTALLATIONS...................................................................................................................................5
CONNECTIONS......................................................................................................................................5
Tap connections .........................................................................................................................6
Cable Connections .....................................................................................................................6
FINAL INSPECTION PRIOR TO ENERGIZATION ........................................................................6
Electrical Inspection .................................................................................................................. 6
Mechanical Inspection............................................................................................................... 7
MAINTENANCE AND PERIODIC INSPECTION............................................................................. 7
Bolt Tightness.............................................................................................................................7
Inspection and Testing ..............................................................................................................7
Routine Field Testing ................................................................................................................8
1. Insulation Resistance Test ...................................................................................8
2. Connection Test....................................................................................................9
3. Mechanical Operation..........................................................................................9
TRANSFORMER MAINTENANCE.....................................................................................................9
Inspection during operation......................................................................................................9
Maintenance during operation .................................................................................................9
Inspection and Measures to be taken during downtime ........................................................9
Inspection of oil leaks and precautions to be taken..................................................9
Inspection Measurements .........................................................................................................10
Opening/Resealing Sealed type Transformers ........................................................................ 10
FUSE REPLACEMENT PROCEDURE ............................................................................................... 11
LOW VOLTAGE CIRCUIT BREAKER MAINTENANCE .............................................................. 11
General ....................................................................................................................................... 12

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INTRODUCTION
The product to which this manual refers should be installed, commissioned, operated and maintained
under the supervision of a competent Electrical Engineer in accordance ith elevant tatutory
requirements and good engineering practice, including Codes of Practice where applicable, and properly
used within the terms of the specification.
The instructions in this manual should familiarize qualified personal with the proper procedures to keep
all new unit(s) in proper operating condition. These instructions for installation, operation and
maintenance of Package Compact Substation should be read carefully and used as a guide during
installation and initial operation.
These instructions do not propose to cover all details or variations in equipment, nor to provide for every
contingency to be met in connection with installation, operation, or maintenance. Should further
information be desired, or particular problems arise which are not covered, please contact the nearest
ABB office.
We would in particular stress the importance of care in:
•Site selection and design, embodying features that provide adequate ventilation, protection and
security and which have taken account of appropriate fire, moisture and explosion hazards.
•Jointing.
•Earthing.
•Selection and setting of electrical protection in primary and secondary, against overload,
overvoltage and short-circuit.
•Carrying out regular inspection and electrical and mechanical maintenance.
The Package Compact Substation(s) covered by these instructions have been repeatedly nspected nd
tested to meet all applicable standards of IEC, to ensure you of a first-rate quality product, which should
give many years of satisfactory performance.
The specific ratings of each Package Compact Substation are shown on the drawings.
File these instructions in a readily accessible place together with drawings and descriptive ata f he
Package Compact Substation. These instructions will be a guide to proper maintenance of the equipment
and prolong its life and usefulness.
GENERAL
These Package Compact Substations are locally manufactured in the Kingdom of Saudi Arabia by ABB
Electrical Industries Co. Ltd., part of the ABB group world-wide to meet the environmental conditions
of the Kingdom, neighboring Gulf countries and other similar places for outdoor installations.

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The Package Compact Substations are completely self-contained, mounted on an integral base, factory
assembled in a totally enclosed, aesthetically and acceptable cladding, vandal-proof, vermin-proof and
weather-proof housing ready for installation into position on a concrete base pad or pier.
The base frame is of welded structural steel and been hot-dipped galvanized after fabrication to assure
affective corrosion resistance in service.
Housing of the Package Compact Substation is made of special material called ALUZINK, a sheet steel
with a metallic alloy coating. The alloy consists of 55% aluminum and 43.4% zinc. This provides
optimum corrosion protection.
The housing has three compartments, separated with ALUZINK sheet. The transformer compartment is
completely separated from the medium voltage and low voltage compartments.
RECEIVING / INSPECTION / STORAGE
The Package Compact Substation is shipped from the factory ready for installation on site. It has been
submitted to all normal routine tests before being shipped, and it is not required to do any voltage testing
before putting it into service, provided the substation has not sustained any damage during transportation.
Immediately upon receipt of the Package Compact Substation, examine them to determine if any damage
or loss was sustained during transit. If abuse or rough handling is evident, file a damage claim with carrier
and promptly notify the nearest ABB office. ABB ELECTRICAL INDUSTRIES CO. LTD. is not
responsible for damage of goods after delivery to the carrier; however, we will lend assistance if notified
of claims.
PERSONNEL SAFETY
The first and most important requirements are the protection against contact with live parts during normal
service as well as maintenance or modifications.
This is the reason why all live parts have been metal enclosed, so that when the parts are live and the
Package Compact Substation doors are open, no one can be able to touch them.
Also, it is safe in case any short-circuiting or sparking occurs at the busbars.
VENTILATION
Transformer compartment has been provided with sand trap louvers, to prevent ingress of sand and that
proper air circulation should take place.
EARTHING
Proper earthing busbar has been provided.
HANDLING
Lifting lugs has been provided on top of four corners of the housing for lifting the DPS by crane and
chains as a single unit, otherwise this can be done by a forklift of sufficient capacity, but the lifting fork
must be positioned under the transformer portion.

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INSTALLATIONS
A clean, flat surface capable of supporting the Package Compact Substation unit weight is the
only requirement for a foundation. It is, however, important that adequate accessibility,
ventilation and ease of inspection of the unit must be provided.
In all installation work, the safety regulations for electrical installations have to be observed.
CONNECTIONS
Each Package Compact Substation must be permanently grounded or earthed by connecting an
affective recognised ground or earth as prescribed by the latest applicable edition of IEC or
ANSI requirements.
The Package Compact Substation is designed to operate with a solidly grounded neutral system.
The neutral connection should be solidly and permanently grounded.
Tap connections
SAFETY NOTES FOR OPERATIONS
1. DO NOT LIFT OR MOVE A TRANSFORMER OR PACKAGE COMPACT
SUBSTATION WITHOUT ADEQUATE EQUIPMENT AND PRECAUTIONS.
2. TERMINALS ARE FOR ELECTRICAL LOADING ONLY.
3. DO NOT MAKE ANY CONNECTIONS THAT ARE NOT AUTHORIZED BY THE
NAMEPLATE OR CONNECTION DIAGRAMS.
4. DO NOT ENERGIZE THE SUBSTATION WITHOUT PROPERLY MADE GROUND
OR EARTH CONNECTIONS.
5. DO NOT ATTEMPT TO CHANGE THE TAP SETTINGS WHILE THE
TRANSFORMER IS ENERGIZED FROM EITHER THE HIGH VOLTAGE OR LOW
VOLTAGE SIDE.
6. DO NOT CHANGE CONNECTIONS OF A TRANSFORMER THAT IS UNDER
EXCITATION.
7. DO NOT TAMPER WITH INTERLOCKS, ALARM AND CONTROL CIRCUIT.
8. DO NOT REMOVE COVER PLATES OR ACCESSORIES WHILE THE SUBSTATION
IS ENERGIZED.
WARNING WARNING WARNING WARNING WARNING WARNING
BEFORE ENERGIZING OR PLACING ANY UNIT INTO SERVICE AFTER EXTENDED
STORAGE, A CHECK OF THE INSULATION RESISTANCE
SHOULD BE MADE.
WARNING WARNING WARNING WARNING WARNING WARNING
A POOR GROUND OR EARTHING MAY RESULT IN LOSS OF LIFE OR
DAMAGE TO THE EQUIPMENT. AN EFFECTIVE LOW RESISTANCE
GROUND IS ESSENTIAL FOR PROPER OPERATION.