Volume Ii - 250kva Trensformers, Ner, Nic & Ancillary Electrical Equipment PDF

STATE OF KUWAIT
MINISTRY OF ELECTRICITY AND WATER -

KUWAIT
SUPPLY AND INSTALLATION OF
SAAD AL ABDULLA ‘A’, ‘B’, ‘C’ & ‘D’ 132/11kV
SUBSTATION
Contract No. ME/EW/C/3377-2005/2006
OPERATION & MAINTENANCE

MANUAL
250kVA TRANSFORMERS,
NEUTRAL EARTHING RESISTORS,
NEUTRAL ISOLATOR CABINETS &
ANCILLARY ELECTRICAL
EQUIPMENT
VOLUME II
MITSUBISHI ELECTRIC
CORPORATION
TOKYO, JAPAN
MINISTRY OF ELECTRICITY AND WATER - KUWAIT
SAAD AL ABDULLA ‘A’, ‘B’, ‘C’ & ‘D’ 132/11kV SUBSTATION
Operational and Maintenance Manuals
Contents
Volumes I to VIII
Volume I – 145kV Gas Insulated Switchgear and Cranes
Section 1 – 145kV Gas Insulated Switchgear
Section 2 – Cranes
☞Volume II – 250kVA Transformers, Neutral Earthing Resistors,

Neutral Isolator Cabinets & Ancillary Electrical Equipment
Section 1 – 250kVA 11/0.433kV Transformers
Section 2 – Neutral Earthing Resistors & Neutral Isolator Cabinets
Section 3 – Low Voltage 415V AC Distribution Boards
Section 4 – Power Cables
Section 5 - Control, Relay, Pilot Marshalling, Telemetry Terminal Transfer panels
Volume III – 30MVA Transformers
30MVA 132/11.5kV Transformers
Volume IV – 11kV Metal clad Switchgear
11kV Metal clad Switchgear
Volume V – Batteries and Chargers
Section 1 – Control system - Battery, Charger and DC distribution board
Section 2 – Trip system - Battery, Charger and DC distribution board
Section 3 – Emergency system – Battery and Charger
-1-
Volume VI – Protection and Control Relays
Part 1
AREVA – Biased differential transformer protection - MICOM P631
Part 2
Section 1 – SIEMENS – Busbar Protection – SIPROTEC 7SS60
Section 2 – SIEMENS – Line Differential Protection – SIPROTEC 7SD610
Part 3
AREVA – Non Directional Overcurrent & Earth Fault Relay

MICOM P120 & P121
Part 4
Section 1 – AREVA – Directional Overcurrent & Earth Fault Relay

MICOM P127
Section 2 – AREVA – Breaker Failure Protection MICOM P821
Part 5
Section 1 – REYROLLE – Earth Fault Relay ARGUS-1
Section 2 – REYROLLE – Line Differential Protection SOLKOR-N
Section 3 – REYROLLE – Line Differential Protection SOLKOR-Rf
Section 4 – REYROLLE – RVM Voltage Regulation Relay SUPERTAPP
Section 5 – AREVA – Test Blocks MMLG 01
Section 6 – FUJI – Fault Indicators
Section 7 – FUJI – Semaphore Relays
Section 8 – TECSYSTEM – Temperature Monitoring Relay T-119
Section 9 – ENERDIS – Transducers TRIAD
Section 10 – CROMPTON – Meters
-2-
Volume VII - Intertrip Equipment
Intertrip Equipment – NSD570
Volume VIII - Fire Fighting
Section 1 – Water Fire Fighting System
Section 2 – Mobile Fire Extinguishers
Section 3– Fire Alarm System
Section 4– Fire Alarm and Detection Panels
-3-
CAST RESIN TRANSFORMER
OPERATING INSTRUCTIONS
&
MAINTENANCE MANUAL
MAN_07082
Subject Three phase transformer, type TAT/R

AN cooling, degree of protection IP 31
Rating kVA 250
Voltages: 11000±2x2.5%/433V– 50Hz
Connection symbol: Dyn11
Serial no. 65830-65831-65832-65833
65834-65835-65836-65837
Customer MITSUBISHI ELECTRIC CORPORATION
Order 094-MG9403-00001
Ref. MINISTRY OF ENERGY – KUWAIT
Supply and installation of 4no. 132/11KV SAAD AL ABDULLA A,B,C & D Substation
and
Extension of 1no. 33KV FEDERER AT UM AL-AISH Substation
I.LORA A.COSTA I.LORA 26/07/07 First Issue 00

DRAW VERIFIED APPROVED DATE REV. DESCRIPTION REV.
1
Ocrev srl
Via dell’ Industria 28 - 36070 Castelgomberto VI – ITALY
MAN_07082
INDEX
- OVERVIEW.
- PACKING.
- HANDLING INSTRUCTIONS.
- STORAGE.
- INSTALLATION.
- CONNECTING TO THE MAINS.
- RATIO OF TRASFORMATION ADJUSTMENT.
- ENERGIZING OF THE TRANSFORMER.
- MAINTENANCE.
- OVERLOADS.
- SPARE PART.
- DRAWINGS.
( RATING PLATE)
( OVERALL DIMENSIONS)
( AUXILIARY CIRCUITS WIRING DIAGRAM)
- ANNEX
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OVERVIEW.
The transformers in the TAT/R series, made by OCREV, comply with the current standards
CEI 14-8 and IEC 60076-11.
The difference of this type of transformer compared to impregnated dry types lies in the
windings which are completely vacuum encapsulated ion epoxy resin forming a compact
mass which, besides protecting the winding from the damp, dust and other polluting
substances, guarantees good insulation of the live parts and an excellent behaviour in the
event of short circuits.
PACKING.
Humidity does not normally influence how cast resin transformers work. They will not need
any packing if the distance to be travelled is short provided they are protected from the rain.
If the distance, or storage is long however or if they are going to be exposed to bad weather
for any length of time, we suggest covering them with a plastic packing material. If they are
to be shipped overseas pack them inside wooden crate/case or containers.
HANDLING INSTRUCTION.
To lift the unpacked transformer use the holes provided or, if provided, they eye bolts on the
top.
We recommended lifting the transformer with the aid of 4 cables with a maximum angle of
60°. For moving along the floor use sliding rollers placing them in the direction you want to
go.
Under no circumstance lean against the windings or their connections when moving the
transformer. Use only the metal points of support. Failure to follow these instruction could
damage the transformer.
STORAGE.
The best place to store resin transformers is a dry, well ventilated place. To prevent dust from
collecting, cover the transformer with a sheet of plastic. After a long period in the warehouse
at temperature of below 0°C or in a very damp place, the transformer must be dried before
energising it.
To prevent damage, any unusual storage conditions which may lead to special consideration,
(warning: the usual storage temperature never exceeding +40°C and –5°C).
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INSTALLATION.
IMPORTANT: the installation and the energising should be carried out by trained people.
Cast resin transformers are designed for indoor installation, having an IP00 level of
protection.
For this reason, the place of installation must be dry and completely waterproof. If the
transformer is to be installed outdoors it must be placed inside a cubicle with a minimum
level of protection equal to IP23.
Certain measures must be taken during installation.
- WARNING: all the operations on the transformer must be executed using the scales or
platform. NOT TO TREAD ON THE TRANSFORMER.
- All packing material, fixing and lifting means must be removed.
- Clean the transformer if necessary, especially the channels trough which cooling air
flows.
- Check the windings and connections have not moved, that the compression bolts on the
top wedges and the tie rods on the nucleus are correctly positioned and secure.
- Don’t remove and don’t modified the distance(phase-phase; phase-earth) of the electrical
connections of transformer.
- Lock the rollers so the transformer cannot move. Damper blocks can be used which,
besides locking the rollers, will considerably reduce noise.
- All parts or accessories disassembled to facilitate transport must be reassembled
following the suitable instruction.
- Pay particular attention to the place of installation which must be adequately ventilated to
guarantee effective cooling of the transformer.
A cooling air supply must be provided for transformers placed indoor or a metal enclosure. A
good ventilation system has to permit the entrance of fresh air from the section(sq. m) S
placed on the base and the exit of warm air from the section (sq. m) S1 placed on the top of
opposite side at the height H (m) from the entry.
FORMULA:
S= 0.188P ; S1= 1.10xS
√H
P = transformer total losses in (KW);
S = entry surface(without possible grate) in (sq. m);
S1= exit surface(without possible grate) (in sq. m);
H = horizontal distance between the two sections (m).
If a sufficient cooling surface cannot be provided, it is necessary to employ a machanical
activated means of ventilation. The air flow should be 4.5m³ per minute for each KW loss
which corresponds to an air temperature of 12 °C approximately.
- Maximum ambient temperature 52°C
- Windings temperature rise 80K / 80K
- The monitoring temperature device will be settled: alarm 140°C; trip 150°C
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Respect the specified insulating distance from the windings and other not insulated parts
under voltage of transformer and the concrete wall or iron grilled (see table below).
Insulation distance from live part of transformer

Insulation Class Distance from concrete wall Distance from iron grilled
(KV) (mm) (mm)
3.6 150 150
7.2 150 200
12 150 250
17.5 220 300
24 240 300
36 320 320
CONNECTING TO THE MAINS.
Prior to energising the transformer there are a few points to be considered:

- All the electrical connections must be well secure and their contact surface must be
sufficiently large and thoroughly clean;
After the HV/LV cables have been connected, carried out: by verify the tightness
connections/earthings bolts to the approximate values:
joint screw size screw class torque
CU/CU plate M10 8.8 50Nm
Links of tap changer M12 Brass 20Nm
H.V connexion M20 Brass 80Nm
keeping count of the respective phase sequence, make sure, before applying energy,
(Terminal board connections must be properly tight to prevent overheating of the joint);
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- The cables and, of course, all the connections, must be at safe distance from live parts
(see table on this subject);
Insulation class Shock peak Minimum distance (mm)

(kV) (kV) according to IEC 60076-3
3.6 40 60
7.2 60 90
12 75 110
17.5 95 170
24 125 210
36 170 280
- Check that voltage variation and adjustment links are positioned according to the
enclosed diagrams and that columns have the same connections arrangements.
- The transformer must be connected to earth with the appropriate terminal.
- Any control temperature devices must be connected and checked to see that they carry
out their function.
- If the transformer is equipped with fans for forced ventilation, check functioning of the
control circuits and rotation direction of the fans.
RATIO OF TRASFORMATION ADJUSTMENT.
The transformers in the TAT/R series are equipped with a ratio of transformation adjustment.
This adjustment is agreed upon with the customer beforehand and can have a minimum of 3
positions (±5% of the nominal value). A greater number of position is possible if requested.
Adjustment is carried out phase by phase by moving the links on the front of H.V. columns.
Particular attention must be paid in placing the links: they must be arranged in the same
position on three H:V: columns.
ATTENTION:
before doing any work on the transformer make certain it is disconnected from the
electricity mains.
Under no circumstances must the transformer be touched when it is energised. Even
going beyond the insulation distance could be a hazard source for people and things.
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STARTING THE TRANSFORMER.
All the connecting points of the auxiliary circuits and accessories must be installed at a
distance far enough away from the high voltage point (windings, connectors and terminals).
The distances to comply with are given in the following table:
Insulation Shock peak Minimum distance

Class voltage according
( kV ) ( kV ) to IEC 60076-3
3,6 40 60
7,2 60 90
12 75 110
17,5 95 170
24 125 210
36 170 280
For parallel operation with other transformers, the transformer must respect the following
conditions:
a) It must belong to the same vector group as the transformers to be used in parallel,
according to the following table:
Three-phase transformer connections
0 Yy0 Dd0 Dz0

1 Yd1 Dy1 Yz1
5 Yd5 Dy5 Yz5
6 Yy6 Dd6 Dz6
11 Yd11 Dy11 Yz11
2 Dd2 Dz2
4 Dd4 Dz4
7 Yd7 Dy7 Yz7
8 Dd8 Dz8
10 Dd10 Dz10
b) Identical value of ‘Short-Circuit Current’, with only the tolerance foreseen by the
Standards, of the other transformers meant for parallel connection.
Make sure that all tools or other object used in installation are accounted for and removed
from the transformer.
7
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MAN_07082
MAINTENANCE.
The transformer must be out of service and grounded.

Cast resin transformer do not normally need any maintenance but it is good practice, at
regular intervals, to:
- remove any dust on the transformer by dry air and rags, and to make sure the cooling
channels are not clogged;
- check tightness of the connections;
- make sure the control devices are all working properly.
table. Recommended Maintenance Schedule

Just prior to Three month after After
Check Period Energising Energising Once a
Year
1. Remove any dust from the transformer X X X
2. Verify that the cooling channel are not X X X
clogged
3. Check the tightness of the Connections X X X
See chapter ( connecting to the mains )
4. Wiring & Circuits X X
5. Control of PT 100 device by Ohm meter X X
at the corresponding windings
temperature
SPARE PARTS.
The cast resin transformers of our production range are assembled according to a modular
system. Their disassembly is only allowed in our workshop.
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OVERLOADS.
Our cast resin transformers are designed to produce their rated output for an unlimited time,
observing the temperatures indicated by the standards.
Unexpected overloads will shorten transformer life.
On the other hand, a transformer can be subject to temporary overloading under well defined
conditions. The duration and value of the overload depend on the power produced and room
temperature at the time of the overload. So with a time constant which, in this case is half an
hour, the permitted overload with a room temperature of 20° C will be:
Duration of the overload (Hours)
12 8 4 2 1
Preliminary
load in %
of the rated Overload in % of In (nominal current)
output
25 6 8 15 25 32
50 6 8 15 22 30
75 5 7 13 22 27
This table has been taken from the CEI 60905 standard “guide for loading dry
transformers”.
Average heating of the windings equal to 100 K for dry transformers in class F has been
taken into account. The absolute temperature that the hottest point in the windings can reach
is 190° C. This temperature must not exceeded for any reason.
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DRAWINGS:
- ( RATING PLATE TS 1976TR)
- ( OVERALL DIMENSIONS CP 2768 AND CP 2769 and CP 2770)
- ( AUXILIARY CIRCUITS WIRING DIAGRAM TS 2123SC)
10
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ANNEX
PTC THERMAL DETECTOR
11
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MITSUBISHI ELECTRIC EUROPE
for
SAAD AL ABDULLA ‘A, B, C & D’ AND UM
AL-AISH ‘M’ SUBSTATIONS
CONTRACT No: ME/EW/C/3377-2005/2006
PURCHASE ORDER NO: 0-94-MG9403-00002
TECHNICAL MANUAL
11.0 kV NEUTRAL EARTHING RESISTORS
SUPPLIED BY:
Cressall Resistors Ltd.

Evington Valley Road
Leicester
LE5 5LZ
Tel: 0116 2733633

Fax: 0116 2737911
Contract No. CR21237
TDS015A
Equipment Supplied
Cressall Neutral Earthing Resistors
16 off – 11.0 kV System voltage,

8.0 Ω±10%, 800 A for 30 secs.
Mounted in a Stainless Steel enclosure
To design SDS – 3887
Serial No. CR21237/1-1 to 16
CONTENTS
TDS015A
Section Title
0 Safety Instructions
1 General Description
2 Unpacking & Lifting
3 Site Installation
4 Maintenance
5 Replacement Parts
6 Documents
TDS015A
Section 0
Safety Instructions
1 Compliance with Instructions in this Manual
The Purchaser/User should comply with the instructions and information given in
this manual and ensure that all personnel to be associated with the apparatus
supplied under this contract are made familiar with the information contained
herein.
2 Installation
The Purchaser/User should ensure that the apparatus supplied under this contract
is correctly installed in a suitable location by technically qualified and competent
persons.
Apparatus supplied as loose components, devices or sub-assemblies could, when

energised, constitute a safety hazard. The Purchaser/User should ensure that
such apparatus is installed in a secure location and that adequate safety
information about the installation is provided to all personnel to be associated
with it.
3 Operation & Maintenance
3.1 Guidance Notes for Users on the Safety of Personnel
The rules for ensuring the safety of personnel can be summarised as follows:-
(a) During Normal Use ensure that the plant operators:
- are fully conversant with all controls, particularly those for emergency
shutdown
- comply with safety warning notices and keep all enclosures shut
- are trained to recognise signs of maloperation and know what action to take in
the event of trouble or difficulty
(b) During Maintenance, Testing etc. ensure that only technically competent and
authorised persons are permitted to carry out work and that they:
- comply with statutory requirements
- are fully conversant with the apparatus and the system of which it
is a part, and recognise the safety hazards which could arise, e.g. back feed.
TDS015A
- isolate the apparatus completely (an Isolator is not normally provided with a
Neutral Earthing Resistor, before carrying out any work it must be isolated
elsewhere) before opening enclosures and prove it to be dead before starting
work. Precautions must be taken to ensure that the isolated apparatus cannot
become live whilst any work is being carried out.
- comply with safe working procedures for the safety of themselves and of
others, including the use of temporary barriers and warning notices.
- are conversant with the information provided, particularly on matters

relating to safety
- recognise the hazards which can arise when working on live apparatus and
take all the necessary precautions
- Functionally check the apparatus and then mechanically and/or

electrically test it in accordance with this manual and good working
practice before putting the apparatus back in service
- take account of the possibility that the apparatus may have been modified
without proper reference to the manufacturer and take extreme caution at
all times before, during and after any work is carried out
If there is any doubt as to the correct and safe method of working then further assistance
should be sought from the supplier.
3.2 Skills Required for Specific Tasks
To ensure that the apparatus is safe for use under normal healthy plant operating
conditions:
- it has been designed and tested in accordance with relevant British European
and International Standards
- information is provided in this manual about the conditions necessary for

safety and about any hazards which are reasonable foreseeable during normal
use, together with precautions to be taken to counteract them.
However the Purchaser/User should ensure that the apparatus is maintained in

a safe condition, and if technically competent and authorised personnel have to
gain access to apparatus which is not made completely safe as recommended,
everyone under whose authority these persons act should ensure that appropriate
safety procedures are generated and are complied with.
The apparatus covered by this manual has been allocated the Apparatus Grade
stated below. Reference to the Apparatus/Task/Skill Level Schedule enables the
user to select personnel to carry out specific tasks requiring access
to the apparatus.
TDS015A
APPARATUS/TASK/SKILL LEVEL SCHEDULE FOR WORKING ON THE APPARATUS
APPARATUS MINIMUM SKILL LEVEL REQUIRED FOR
GRADE DEGREE OF INTEGRAL 100% SETTLING, SETTLING, SPECIAL

ISOLATION PROVIDED FOR ISOLATION & CLEANING, CLEANING, TESTING,
PROVING DEAD ROUTINE ROUTINE COMMISSIONIN
G
MAINTENANCE MAINTENANCE, FAULT FINDING
ROUTINE
TESTING
With Power On With Power On With Power On

100% Isolated or Not 100% or Not 100%
& Proved Dead Isolated Isolated
1 100% isolation by operation C A C C

of the isolators provided
2 Partial isolation only by C A C C

operation of the Isolators
provided. The Purchaser/
User is responsible for 100%
isolation elsewhere
3 No Isolator provided. The C B C C

Purchaser/User is
responsible for any necessary
isolation elsewhere
4 100% Isolation not possible Not Applicable Not Applicable C C

because: Impracticable,
Unreasonable, & or
Undesirable
5 Apparatus supplied as loose C Skill level is C C

items, sub-assemblies etc. to be
for which the Purchaser/User determined by
is responsible for wiring Purchaser/
assembly etc. User
TDS015A
Skill levels as referred to in the Schedule above
SKILL JOB DESCRIPTIONS

LEVEL
PROPOSED BY SUPPLIER USER
Operating and maintenance
staff with NO electrical knowledge
A but fully conversant with the
operation and maintenance of
the apparatus
Maintenance staff with SOME

electrical knowledge and fully
conversant with the operation
B and maintenance of the apparatus
and the system of which it is a
part.
Authorised and competent staff

(e.g Electrician, Commissioning
Engineer) with HIGH degree of
electrical expertise: trained to
C work on live apparatus and
fully conversant with the
apparatus and the system of which
it is a part.
TDS015A
SECTION 1
GENERAL DESCRIPTION
Based on the information provided in your order the resistor provided has been designed to
meet the requirements of IEEE 32 when operated at the rating specified in your order.
The resistor bank is built up from a number of individual, replaceable coils arranged in banks to
meet your specified details.
RP resistors are manufactured from continuous stainless steel alloy strip wound edgewise into
elliptical coils. Each coil is supported by ceramic insulators mounted on a stainless steel centre
support with stainless steel terminals welded to each end. The arrangement freely allows
expansion and contraction of the resistor elements without imposing strain on the coils or
terminals.
The coils are assembled in bank formation for duty at high working temperature.
The coil and bank design distributes specified working voltage across the various levels of
insulation and is fully tested in accordance with the routine test requirements of IEEE-32 1972
before despatch.
The enclosure provided has sufficient creepage and clearances for the voltage specified by
yourselves in your order. The construction allows for the resistor reaching a temperature of
760°C during a full Earth fault.
Cable connections
Incoming and Outgoing Cables:-
These are terminated in separate air insulated cable boxes. An M12 through bushing is
provided between the box and the resistor enclosure.
A removable undrilled gland plate is provided.
Enclosure Earth Connection:-
Two separate M12 terminals are provided on the exterior of the enclosure for bonding
the enclosure to earth.
N.B. When removing covers and gland plates etc. ensure all screws, nuts,
washers etc. are refitted on re-assembly to ensure earthing continuity.
TDS015A
SECTION 2
UNPACKING / LIFTING
2.1 Shipping
Unit is shipped in ready to use state.
2.2 Receiving
Once received, the unit should be unloaded and moved by forklift or crane. At
this point, a preliminary inspection of the unit should be made to ensure proper
handling was practised during shipment. For more on inspection procedures,
see “Site Installation”.
2.3 Lifting
Top mounted eye-bolts are provided for easy handling by crane (minimum angle 45º
between slings & horizontal). A forklift can be used to place the unit providing that
extra precaution is taken to ensure the forks rest against the steel angles of the
enclosure and not the bottom screening.
LIFTING SLING ANGLE DATA

M16 EYE NUTS
MAXIMUM LIFT FOR 4 EYE NUTS = 700 X SINE φ X 4 KG
φ
φ
ANGLE φº MAX LIFT (KG)
90 2800
85 2790
80 2760
75 2700
70 2630
65 2540
60 2420
55 2290
50 2140
45 1980
TDS015A
SECTION 3
SITE INSTALLATION
3.1 Location on Site
The equipment should be located taking heed of the following points:-
a) Access
At least 1000mm is required for access in front of all removable covers , but
subject to local / site regulations which may dictate greater clearances.
Removal of panels will give access to live metal so they must be located in a secure
environment.
b) Ventilation
Neutral Earthing Resistors may become very hot during operation. A free-air flow
environment is required around the resistor enclosure with a recommended minimum of
approximately 250mm.
c) Safe Working
High Temperature - During normal service, either due to steady

state current flow (if specified), or a fault condition, both the issuing air
temperature and the enclosure surface temperature may exceed 100°C.
Equipment or combustible materials must not lie on the top cover of

the enclosure or be in contact with the sides.
3.2 Installation
A flat foundation is required.
The Neutral Earthing Resistor is supplied assembled.
No special tools are required.
Lifting equipment must be capable of lifting the N.E.R., the weight is given on the rating plate.
Place the Neutral Earthing Resistor on the prepared base.
Remove front and back covers.
Drill gland plate as required.
Check fixing integrity of resistors
TDS015A
Examine for signs of damage during transit. i.e. Check that the enclosure and support structure
are undamaged, that there are no broken insulators and that the resistor elements are secure
on their mountings.
Secure the Neutral Earthing Resistor onto its base. For a concrete base, use expanding bolts
or rag bolts which penetrate at least 100mm into solid ground.
Ensure that all connections are tight.
Refit back cover.
Connect incoming cable.
Carry out commissioning checks as detailed below.
Connect outgoing cable. (Resistor Earth).
Refit front cover.
Connect enclosure earth bonding cables as required.
Check all enclosure bolts are tight.
Tightening Torques
Torque N - m
Size St Stl bolts & Screws Bushing connections
M6 7.2 -
M8 17.6 -
M10 35.0 14
M12 61.2 20
M16 152.0 25
M20 296.4 35
M24 512.8 45
3.3 Commissioning
TDS015A
i) Check resistance value, this must be the value stamped on the rating
plate ±10%.
ii) With earth connection disconnected check insulation resistance, this

should be greater than 100MΩ (dependent on site levels of humidity)
Alternatively: Carry out an applied potential test, maximum applied

voltage = ( 2.25 x phase voltage ) + 2000V at 50 Hertz.
N.B. If the Earth Bushing is on the outside of the enclosure, the maximum applied
potential shall be 10kV.
Do not energise Current Transformers with the Secondary Winding open circuit.
iii) Reconnect earth cable
3.4 De-commissioning
i) Ensure the equipment is isolated and that the remainder of any electrical system it
formed part of can function safely without the Neutral Earthing Resistor in circuit.
ii) Remove Cable box cover, disconnect and remove incoming cable.
iii) Remove outgoing earth and bonding earth cables.
iv) Remove foundation bolts.
SECTION 4
MAINTENANCE
TDS015A
The equipment must be completely isolated from the power supply before any
maintenance is carried out.
Routine:
Very little maintenance is required on this equipment, but maintenance inspections should be
carried out at regular periods to ensure that the equipment is kept in a good and reliable
condition. The frequency of the inspections is dependant upon site conditions i.e. atmospheric
pollution, safe access to the equipment etc. but initially could be on a 6 monthly basis.
Access to the resistor units is obtained by removing either the front or back cover and lifting the
cover away.
Remove cable box cover and:
(a) Remove all dirt from cable terminations, and porcelain insulators.
(b) Check that all connections are sound and that fixing nuts and screws are tight.
(c) Inspect enclosure for damage to paint finish, if applicable, and make good
any damaged areas.
After inspection, ensure that the covers of the enclosure are securely fastened in
position.
After a System Fault:
Remove end covers and check:
a) that the support insulators are not broken.
b) that the Resistor Elements are undamaged. Whilst they will show signs of having been very
hot, they should not be distorted and the ceramic supports should not be cracked or
disintegrating.
c) that the incoming cable connection is sound. Also check the earth connections from the
resistor and the frame.
d) Check that all fastenings are tight and refit covers.
TDS015A
SECTION 5
REPLACEMENT PARTS
Should it be necessary to replace any part of this equipment, customer should

apply to Cressall Resistors, quoting the serial number of the equipment which is to be
found on the rating plate and a description of the part required.
The principal electrical components are as follows:-
Tittle Part No.
Resistor element RP9G118GR1J
Base insulators 70205
Inter Bank insulators 70205
Neutral bushing RE4/T44118/1
Earth bushing 95250
TDS015A
SECTION 6
DOCUMENTS
Test Report
Certificate of Conformity
Data Sheet
NER Arrangement Drawing No. 107933 issue B
TDS015A
TEST REPORT
DATE :
PRODUCT: NEUTRAL EARTHING RESISTOR FOR AN 11kV SYSTEM.
RATED 800A FOR 30 SECONDS. 8Ω ± 10%. CONTRACT No. CR 21237/1
IP23 ALUZINK ENCLOSURE WITH 2 x IP54 CABLE BOXES DESIGN No. SDS – 4739
OHMMETER No. TE 015
FLASH TESTER No. TE 011
INSULATION RESISTANCE
CUSTOMER: MITSUBISHI ELECTRIC CORPORATION TESTER No. TE 075
ORDER No: 0-94-MG9403-00002
Ω Ω Ω
Ser. No Section Nominal Measure Ser. No Section Nominal Measured Ser. No Section Nominal Measured
d
1 N–E 8⋅00 10 N–E 8⋅00
2 N–E 8⋅00 11 N–E 8⋅00
3 N–E 8⋅00 12 N–E 8⋅00
4 N–E 8⋅00 13 N–E 8⋅00
5 N–E 8⋅00 14 N–E 8⋅00
6 N–E 8⋅00 15 N–E 8⋅00
7 N–E 8⋅00 16 N–E 8⋅00
8 N–E 8⋅00
9 N–E 8⋅00
INSULATION RESISTANCE: >999MΩ @ 1000V EARTH INTEGRITY CHECKED: 9
AMBIENT TEMPERATURE: 19º C ± 2º C
POWER FREQUENCY TESTS:

2 kV for 5 Seconds LIVE METAL to CENTRE SUPPORTS
4 kV for 1 Min. LIVE METAL to END FRAMES
4 kV for 1 Min. BETWEEN TIERED END FRAMES
^7 kV for 1 Min. ACROSS FOOT INSULATORS (GRADED INSULATION)
4 kV for 1 Min. L.V. BUSHING to ENCLOSURE
*16⋅5 kV for 1 Min. LIVE METAL to ENCLOSURE (LV BUSHING DISCONNECTED)
Vp = Phase Voltage * = Vp x 2⋅25 + 2 ^= (Vp) x 2⋅25 + 2

(No. of Tiers)
Peter Chinnery
P Chinnery
On behalf of CRESSALL RESISTORS Ltd
TDS015A
CERTIFICATE OF CONFORMITY
Serial No: CR21237/001

Contract: ME/EW/C/3377-2005/2006
P/O No: 0-94-MG9403-00002
Works Order: CR21237
To:
Mitsubishi Electric Corporation
P.O. Box 2707
Salmiya
22028
Kuwait
Contract Description Specification Quantity Remarks

Item No. Drawing No.
1 CRESSALL Neutral Earthing 107933

Resistor rated for 11.0kV Design No. 16
system voltage, 8.0 ohms, SDS-4739
800 amps for 30 seconds
Certified that the whole of the supplies detailed hereon have been inspected, tested and
unless otherwise stated above, conform in all respects to the specifications, drawings and
contract/order relative hereto.
Signed Date: 27.07.07
Peter Chinnery
Peter Chinnery
For and on behalf of

CRESSALL RESISTORS
TDS015A
DATA SHEET NEUTRAL EARTHING RESISTOR
Rated Line Voltage (kV) 11.0 Rated Current (A) 800
Rated Phase Voltage (kV) 6.35 Continuous Current (A) 0
Rated Impulse Voltage (kV) 75 Rated Time (Sec.) 30
Resistance 20ºC (Ω±10%) 8.0 Resistor Temp. Rise (ºC) 760 max
Enclosure
Enclosure Clasification IP23 Enclosure Material Stain./stl
Cable Box: Neutral IP54 Cable Entry: Neutral

Earth Earth
Paint Finish Unpainted Colour Natural
Approx. Weight (kg) 450
Special Features
Current Transformer: Ratio N/A
Class
Burden
Isolator N/A
TDS015A
‘AS BUILT’
TDS015A
‘AS BUILT’
TDS015A
MITSUBISHI ELECTRIC EUROPE
for
SAAD AL ABDULLA ‘A, B, C & D’ AND UM
AL-AISH ‘M’ SUBSTATIONS
CONTRACT No: ME/EW/C/3377-2005/2006
PURCHASE ORDER NO: 0-94-MG9403-00002
TECHNICAL MANUAL
11.0 kV CHANGEOVER SWITCH CABINETS
SUPPLIED BY:
Cressall Resistors Ltd.

Evington Valley Road
Leicester
LE5 5LZ
Tel: 0116 2733633

Fax: 0116 2737911
Contract No. CR21237
TDS015A
Equipment Supplied
Cressall Neutral Earthing Resistors
16 off – 11.0 kV, 630 A

Two Off Load Isolators
Mounted in a Stainless Steel enclosure
Complete with two Current Transformers
To design SDS – 4783
Serial No. CR21237/2-1 to 16
CONTENTS
TDS015A
Section Title
0 Safety Instructions
1 General Description
2 Unpacking & Lifting
3 Site Installation
4 Maintenance
5 Replacement Parts
6 Documents
TDS015A
Section 0
Safety Instructions
1 Compliance with Instructions in this Manual
The Purchaser/User should comply with the instructions and information given in
this manual and ensure that all personnel to be associated with the apparatus
supplied under this contract are made familiar with the information contained
herein.
2 Installation
The Purchaser/User should ensure that the apparatus supplied under this contract
is correctly installed in a suitable location by technically qualified and competent
persons.
Apparatus supplied as loose components, devices or sub-assemblies could, when

energised, constitute a safety hazard. The Purchaser/User should ensure that
such apparatus is installed in a secure location and that adequate safety
information about the installation is provided to all personnel to be associated
with it.
3 Operation & Maintenance
3.1 Guidance Notes for Users on the Safety of Personnel
The rules for ensuring the safety of personnel can be summarised as follows:-
(a) During Normal Use ensure that the plant operators:
- are fully conversant with all controls, particularly those for emergency
shutdown
- comply with safety warning notices and keep all enclosures shut
- are trained to recognise signs of maloperation and know what action to take in
the event of trouble or difficulty
(b) During Maintenance, Testing etc. ensure that only technically competent and
authorised persons are permitted to carry out work and that they:
- comply with statutory requirements
- are fully conversant with the apparatus and the system of which it
is a part, and recognise the safety hazards which could arise, e.g. back feed.
TDS015A
- isolate the apparatus completely (an Isolator is not normally provided with a
Neutral Earthing Resistor, before carrying out any work it must be isolated
elsewhere) before opening enclosures and prove it to be dead before starting
work. Precautions must be taken to ensure that the isolated apparatus cannot
become live whilst any work is being carried out.
- comply with safe working procedures for the safety of themselves and of
others, including the use of temporary barriers and warning notices.
- are conversant with the information provided, particularly on matters

relating to safety
- recognise the hazards which can arise when working on live apparatus and
take all the necessary precautions
- Functionally check the apparatus and then mechanically and/or

electrically test it in accordance with this manual and good working
practice before putting the apparatus back in service
- take account of the possibility that the apparatus may have been modified
without proper reference to the manufacturer and take extreme caution at
all times before, during and after any work is carried out
If there is any doubt as to the correct and safe method of working then further assistance
should be sought from the supplier.
3.2 Skills Required for Specific Tasks
To ensure that the apparatus is safe for use under normal healthy plant operating
conditions:
- it has been designed and tested in accordance with relevant British European
and International Standards
- information is provided in this manual about the conditions necessary for

safety and about any hazards which are reasonable foreseeable during normal
use, together with precautions to be taken to counteract them.
However the Purchaser/User should ensure that the apparatus is maintained in

a safe condition, and if technically competent and authorised personnel have to
gain access to apparatus which is not made completely safe as recommended,
everyone under whose authority these persons act should ensure that appropriate
safety procedures are generated and are complied with.
The apparatus covered by this manual has been allocated the Apparatus Grade
stated below. Reference to the Apparatus/Task/Skill Level Schedule enables the
user to select personnel to carry out specific tasks requiring access
to the apparatus.
TDS015A
APPARATUS/TASK/SKILL LEVEL SCHEDULE FOR WORKING ON THE APPARATUS
APPARATUS MINIMUM SKILL LEVEL REQUIRED FOR
GRADE DEGREE OF INTEGRAL 100% SETTLING, SETTLING, SPECIAL

ISOLATION PROVIDED FOR ISOLATION & CLEANING, CLEANING, TESTING,
PROVING DEAD ROUTINE ROUTINE COMMISSIONIN
G
MAINTENANCE MAINTENANCE, FAULT FINDING
ROUTINE
TESTING
With Power On With Power On With Power On

100% Isolated or Not 100% or Not 100%
& Proved Dead Isolated Isolated
1 100% isolation by operation C A C C

of the isolators provided
2 Partial isolation only by C A C C

operation of the Isolators
provided. The Purchaser/
User is responsible for 100%
isolation elsewhere
3 No Isolator provided. The C B C C

Purchaser/User is
responsible for any necessary
isolation elsewhere
4 100% Isolation not possible Not Applicable Not Applicable C C

because: Impracticable,
Unreasonable, & or
Undesirable
5 Apparatus supplied as loose C Skill level is C C

items, sub-assemblies etc. to be
for which the Purchaser/User determined by
is responsible for wiring Purchaser/
assembly etc. User
TDS015A
Skill levels as referred to in the Schedule above
SKILL JOB DESCRIPTIONS

LEVEL
PROPOSED BY SUPPLIER USER
Operating and maintenance
staff with NO electrical knowledge
A but fully conversant with the
operation and maintenance of
the apparatus
Maintenance staff with SOME

electrical knowledge and fully
conversant with the operation
B and maintenance of the apparatus
and the system of which it is a
part.
Authorised and competent staff

(e.g Electrician, Commissioning
Engineer) with HIGH degree of
electrical expertise: trained to
C work on live apparatus and
fully conversant with the
apparatus and the system of which
it is a part.
TDS015A
SECTION 1
GENERAL DESCRIPTION
This unit consists of two Off Load manually operated Isolators mounted in a stainless steel
cabinet. They are controlled by ‘Castell Locks’, both with the same letter, so that they must both
be closed before the key can be removed.
Provision is made for bottom entry of the cables to the isolators which have a common input
terminal, removable undrilled gland plates are provided.
A ‘Ring Type’ Current Transformer is mounted above the centre input gland plate and also one
above the right hand gland plate round the cable to the Neutral Earthing Resistor which is
mounted in a separate enclosure. The left hand isolator is for direct connection to the Station
Earth system.
Each Isolator has two normally open & two normally closed pairs of auxiliary contacts. These
are wired back to a terminal box on the side of the main enclosure.
Enclosure Earth Connection:-
Two separate M12 terminals are provided on the exterior of the enclosure for bonding
the enclosure to earth.
N.B. When removing covers and gland plates etc. ensure all screws, nuts,
washers etc. are refitted on re-assembly to ensure earthing continuity.
TDS015A
SECTION 2
UNPACKING / LIFTING
2.1 Shipping
Unit is shipped in ready to use state.
2.2 Receiving
Once received, the unit should be unloaded and moved by forklift or crane. At
this point, a preliminary inspection of the unit should be made to ensure proper
handling was practised during shipment. For more on inspection procedures,
see “Site Installation”.
2.3 Lifting
Top mounted eye-bolts are provided for easy handling by crane (minimum angle 45º
between slings & horizontal). A forklift can be used to place the unit providing that
extra precaution is taken to ensure the forks rest against the steel angles of the
enclosure and not the bottom screening.
LIFTING SLING ANGLE DATA

M16 EYE NUTS
MAXIMUM LIFT FOR 4 EYE NUTS = 700 X SINE φ X 4 KG
φ
φ
ANGLE φº MAX LIFT (KG)
90 2800
85 2790
80 2760
75 2700
70 2630
65 2540
60 2420
55 2290
50 2140
45 1980
TDS015A
SECTION 3
SITE INSTALLATION
3.1 Location on Site
The equipment should be located taking heed of the following points:-
a) Access
At least 1000mm is required for access in front of all removable covers , but
subject to local / site regulations which may dictate greater clearances.
Removal of panels will give access to live metal so they must be located in a secure
environment.
b) Ventilation
Neutral Earthing Resistors may become very hot during operation. A free-air flow
environment is required around the resistor enclosure with a recommended minimum of
approximately 250mm.
c) Safe Working
High Temperature - During normal service, either due to steady

state current flow (if specified), or a fault condition, both the issuing air
temperature and the enclosure surface temperature may exceed 100°C.
Equipment or combustible materials must not lie on the top cover of

the enclosure or be in contact with the sides.
3.2 Installation
A flat foundation is required.
The Changeover Switch Cabinet is supplied assembled.
No special tools are required.
Lifting equipment must be capable of lifting the N.E.R., the weight is given on the rating plate.
Place the Cabinet on the prepared base.
Remove front cover.
Drill gland plates as required.
TDS015A
Examine for signs of damage during transit. i.e. Check that the enclosure and support structure
are undamaged, that there are no broken insulators and that the components are secure on
their mountings.
Secure the Cabinet onto its base. For a concrete base, use expanding bolts or rag bolts which
penetrate at least 100mm into solid ground.
Ensure that all connections are tight.
Connect incoming cable.
Connect outgoing cables
Connect the auxiliary wiring.
Refit front cover.
Connect enclosure earth bonding cables as required.
Check all enclosure bolts are tight.
Tightening Torques
Torque N - m
Size St Stl bolts & Screws Bushing connections
M6 7.2 -
M8 17.6 -
M10 35.0 14
M12 61.2 20
M16 152.0 25
M20 296.4 35
M24 512.8 45
TDS015A
3.3 Commissioning
i) Check operation of each Isolator and Castell lock.
ii) Check auxiliary circuits.
Do not energise Current Transformers with the Secondary Winding open circuit.
3.4 De-commissioning
i) Ensure the equipment is isolated and that the remainder of any electrical system it
formed part of can function safely without the Neutral Earthing Resistor in circuit.
ii) Remove cover, disconnect and remove cables.
iii) Remove earth and bonding earth cables.
iv) Remove foundation bolts.
SECTION 4
MAINTENANCE
TDS015A
The equipment must be completely isolated from the power supply before any
maintenance is carried out.
Routine:
Very little maintenance is required on this equipment, but maintenance inspections should be
carried out at regular periods to ensure that the equipment is kept in a good and reliable
condition. The frequency of the inspections is dependant upon site conditions i.e. atmospheric
pollution, safe access to the equipment etc. but initially could be on a 6 monthly basis.
Access to the unit is obtained by removing the front cover and lifting the cover away.
(a) Remove all dirt from cable terminations, and porcelain insulators.
(b) Check that all connections are sound and that fixing nuts and screws are tight.
(c) Inspect enclosure for damage to finish and make good any damaged areas.
(d) Examine isolator contacts for burning and wear. Lubricate with standard
contact grease as necessary
After inspection, ensure that the covers of the enclosure are securely fastened in
position.
After a System Fault:
Remove covers and check:
a) that the support insulators are not broken.
b) that the Isolators are undamaged and operate correctly. Whilst they may show signs of
having been very hot, they should not be distorted and the ceramic supports should not be
cracked or disintegrating.
c) that the cable connections are sound. Also check the earth connections from the resistor and
the frame.
d) Check that all fastenings are tight and refit cover.
SECTION 5
REPLACEMENT PARTS
TDS015A
Should it be necessary to replace any part of this equipment, customer should
apply to Cressall Resistors, quoting the serial number of the equipment which is to be
found on the rating plate and a description of the part required.
The principal electrical components are as follows:-
Tittle Part No.
Isolator (left hand) BA107992/LH/4
Isolator (Right hand) BA107992/RH/4
Support insulator 70215
Castell Interlock 103263
Current Transformer 1600/1 107997
Current Transformer 800/1 107998
TDS015A
SECTION 6
DOCUMENTS
Test Report
Certificate of Conformity
Current Transformer Magnetisation Data
NER Arrangement Drawing No. 107934 issue B
Wiring Diagram 107935 issue B
TEST REPORT
TDS015A
DATE : 14 – 03 – 05
PRODUCT: 12kV 630A CHANGE – OVER SWITCH CUBICLE.
FITTED 2 x CASTELL KEY INTERLOCKED ISOLATORS CONTRACT No. CR 16290/2
EA. C/W 2PRS N/O & 2PRS N/C AUX. CONTACTS. DESIGN No. SDS – 3888
IP23 ALUZINK ENCLOSURE. OHMMETER No. TE N/A
FITTED 2 x C.T.’s. FLASH TESTER No. TE 011
INSULATION RESISTANCE
CUSTOMER: MITSUBISHI ELECTRIC EUROPE TESTER No. TE 075
ORDER No: 30000630 / 999 / B51
Serial No Key No C.T. ‘A’ Serial No. C.T. ‘B’ Serial No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
INSULATION RESISTANCE: >999MΩ @ 1000V EARTH INTEGRITY CHECKED: 9
AMBIENT TEMPERATURE: 18º C ± 3º C
MECHANICAL OPERATION & ELECTRICAL INTEGRITY OF ISOLATOR / AUX. CONTACTS /

LV. WIRING CHECKED: 9
POWER FREQUENCY TESTS:

*16⋅5 kV for 1 Min. LIVE METAL to ENCLOSURE (ISOLATORS CLOSED)
*16⋅5 kV for 1 Min. BETWEEN ISOLATOR TERMINALS (ISOLATORS OPEN)
P Chinnery
On behalf of CRESSALL RESISTORS Ltd
TDS015A
CERTIFICATE OF CONFORMITY
Serial No: CR21237/002

Contract: ME/EW/C/3377-2005/2006
P/O No: 0-94-MG9403-00002
Works Order: CR21237
To:
Mitsubishi Electric Corporation
P.O. Box 2707
Salmiya
22028
Kuwait
Contract Description Specification Quantity Remarks

Item No. Drawing No.
1 CRESSALL 11.0kV, 630 107934

amp Changeover Switch Design No. 16
Cabinet SDS-4783
Certified that the whole of the supplies detailed hereon have been inspected, tested and
unless otherwise stated above, conform in all respects to the specifications, drawings and
contract/order relative hereto.
Signed Date: 27.07.07
Peter Chinnery
Peter Chinnery
For and on behalf of

CRESSALL RESISTORS
TDS015A
RECORDED MAGNETISATION CURVE DATA
Current transformer to IEC / BSEN60044.1:1999

Ratio 1600/1 Class 5P20 Burden (VA) 10VA 50Hz
Max.Rated Secondary Res. at 75ºC (Ω) 6.03 Measured Resistance at 20ºC (Ω) 4.473
Magnetising Current in mA
100% F.L.C.
Serial No. 417V 379V 344V 313V 285V 213V 142V 71V R.E.(%) P.A.(mins)
TDS015A
Current transformer to IEC / BSEN60044.1:1999
Ratio 800/1 Class 10P10 Burden (VA) 15VA 50Hz
Max.Rated Secondary Res. at 75ºC (Ω) 8.91 Measured Resistance at 20ºC (Ω) 6.88
Magnetising Current in mA
100% F.L.C.
Serial No. 207V 189V 171V 156V 142V 106V 71V 36V R.E.(%) P.A.(mins)
TDS015A
‘AS BUILT’
TDS015A
‘AS BUILT’
TDS015A
INSTALLATION & MAINTENANCE
INSTRUCTIONS
FOR
LOW VOLTAGE AC DISTRIBUTION BOARD
PURCHASER : MINISTRY OF ELECTRICITY & WATER,

KUWAIT.
CONTRACTOR : MITSUBISHI ELECTRIC CORPORATION
CONTRACT NO. : ME/EW/C/3377-2005/2006
JULY 2008 (Rev.0) Publication No. AIM/08/53
C:\Documents and Settings\Zikica Tojcic\My Documents\LVAC_manual.DOC Page 1 of 15

INSTALLATION&MAINTENANCE INSTRUCTIONS
FOR LOW VOLTAGE AC DISTRIBUTION BOARD
CONTENTS
1 SAFETY PRECAUTIONS
1.1 General
1.2 Emergency Procedures
1.3 Handling
1.4 Installation and Commissioning
1.5 Maintenance
2 DESCRIPTION OF EQUIPMENT
3 INSTALLATION
3.1 Handling
3.2 Storage
3.3 Erection
3.3.1 General
3.3.2 Framework Jointing
3.4 Connections
3.4.1 Main Busbars
3.4.1.1 Phase & Neutral Busbar
3.4.1.2 Earth Busbars
3.4.2 Secondary Connections
3.4.3 Recommended Torque Settings
3.5 Earthing
3.6 Cabling

4 COMMISSIONING
4.1 Visual Inspection

4.1.1 General
4.1.2 Fuses
4.1.3 Miniature and Moulded Case Circuit Breakers
4.1.4 Contactor, Relay and General Panel Equipments
4.2 Megger & Power frequency(Dielectric) Tests
4.3 Operational Checks
4.4 Energizing
5 OPERATION
5.1 General
5.2 Direction of Operating Handles
6 ROUTINE MAINTENANCE
6.1 General
6.1.1 Safety
6.1.2 Inspection
6.1.3 Megger Test
6.1.4 Operational Check
6.2 Devices
6.2.1 Instruments, Meters and Relays
6.3 Lubrications
7 Transportation to site
7.1 Loading
7.2 Unloading

1.1 GENERAL
It is the duty of all persons, directly or indirectly associated with the

installation, control, operation or maintenance of the equipment to
eliminate or minimize any risks to health or safety.
All persons operating or working on the equipment must be

competent and be aware of any dangers which may arise during
normal operation.
Tools must not be used to gain access to any part without first
referring to the appropriate instructions or drawings. Covers, doors
or screens carrying a warning of live equipment must not be removed
without ensuring that the equipment is first made dead.
1.2 EMERGENCY PROCEDURES
Should an abnormal condition arise, either in the switchgear or its

associated equipment and cables, then the following procedure must
be adopted:
a) Immediately isolate from the supply any area of fault.
b) Should a fault have occurred in or adjacent to an incoming

transformer panel, the associated H.V. circuit breaker must also
be tripped.
c) In case of fire, the mains and standby supplies must be isolated.
d) Do not, under any circumstances, use water to put out a fire in

or around electrical equipment.
e) For personal injury or electric shock, seek immediate medical

advice and attention.
f) After a fault and prior to reinstatement, equipment must always

be checked by a competent person, to ascertain the cause and any
remedial action taken. As soon as possible, thereafter the routine
maintenance programme should be carried out. Work on
H.V./L.V. equipment must always be carried out by authorized
personnel only.

1.3 HANDLING
Each cubicle is fitted with lifting eyes or lifting hooks to assist

handling. Lifting arrangements must be such that the load is carried
evenly between all the eyes/hooks provided and that as far as
possible inclined loading is avoided. It is recommended that
spreader frames must be used to achieve this since the safe working
load of the eyebolt is significantly reduced when inclined loading is
applied.
When rollers are used to assist handling a load bearing plate must be
positioned between the cubicle base and the rollers. Special care
must always be taken to prevent the cubicle toppling over when the
rollers are employed, particularly on uneven or sloping surfaces.
The cubicle must always be transported the right way up. When
packed the case markings indicate the correct positions.
1.4 INSTALLATION AND COMMISSIONING
Information on the design, construction and installation of

equipment to ensure that it is safe and without risk to health when
properly used may be found in:
a) Relevant British Standard Specifications and Codes of Practice.
b) Ministry of Electricity & Water, Kuwait specifications and

regulations.
c) Relevant catalogues and Product Data Sheets of the equipment

manufacturers.
The equipment must be installed or commissioned by or under the

supervision of competent persons in accordance with MEW
Regulations, Statutory Requirements and Instructions specifically
advised by the manufacturer.
1.5 MAINTENANCE
Before carrying out any maintenance work ensures that the

equipment is isolated and safe.
Consult manufacturer's relevant manual covering maintenance and/or

service of the particular equipment before proceeding further.
The incoming supply must be isolated by locking off: H.V. circuit
breakers and fuse switches, generating plant, bus-couplers or

supplies from other switchboards. The isolation should be checked
with suitable reliable test equipment.
While all incoming supplies may have been isolated, certain

auxiliary/control supplies may still be "live", eg. DC tripping
supplies from a battery unit.
Although means of isolation is provided while working on the load

side of devices by opening or tripping the respective circuit device,
measures must be taken to prevent unintended re-closure, eg.
Padlocking in the off position.
These instructions cover AC Distribution Board or Mobile diesel

Generator panel emboding, Moulded Case and Miniature Circuit
Breakers, Switch Fuse, and similar equipments.
Information regarding size, layout, arrangement or devices, ratings,

etc. is given on the general arrangement drawings and the circuit
diagrams supplied with the equipment as part of contract.
3 INSTALLATION
3.1 HANDLING
Cubicles may be lifted using eyebolts or hooks provided or

maneuvered into position on rollers with a load bearing plate
between the base of the cubicle and the rollers. The cubicles must
always be transported the right way up. When packed the case
markings indicate the correct position. See also Section 1.3
regarding handling.
3.2 STORAGE
The equipment must always be stored indoor in dry, clean

conditions, free of contaminating or corrosive atmospheres. It
should be stored in an upright position and where possible switching
devices (circuit breakers, fuse switches, etc.) should be placed in the
"On" position.

3.3 ERECTION
3.3.1 GENERAL
The Distribution Board must be erected on a level and even surface.

If necessary shims or packers should be used between the cubicle
base and the floor to achieve correct alignment. It is recommended
that a minimum of 1 meter clear space be made available all around
the floor mounting panel board for ease of operation/maintenance.
When cubicles have been split for transport check the general
arrangement drawing to ensure that they are erected in the correct
sequence and that all cubicles are present. Each cubicle has
provision for 4 foundation bolts and has 8 fixings securing it to the
adjacent cubicle. The frame fixing screws, busbar fishplates and
fixings are supplied. The foundation bolts should not be tightened
down until the cubicle frame jointing bolts are correctly fitted.
3.3.2 FRAMEWORK JOINTING
Each framework is secured to the adjacent frame with M8 screws

passing through clearance holes in the framework of the cubicles.
Jointing screws are supplied with the busbar fishplates, etc.
3.4 CONNECTIONS
3.4.1 Main Busbars
3.4.1.1 Phase & Neutral Busbar
The busbars mounted in the Switchboard are provided with phase

identification marking.
Beginning with the rear most busbar, place the fishplate to the front
of the busbar and fit with the M10 screws and washers. With all
screws in place ensure that they are correctly tightened (See Section
3.4.3 for recommended torque values). Repeat for the remaining
busbars.
With all fishplates in position and secure, check that electrical

clearances have been maintained. Re-fit main covers.

3.4.1.2 Earth Busbars
The earth busbar of the adjacent panel is jointed with the fishplates,
M10 bolts, nuts and washers provided with the cubicle. Ensure that
the joints are properly tightened.
3.4.2 Secondary Connections
Details of secondary wiring and connections are given on the

relevant schematic/terminal schedule diagrams. All bus wires must
be terminated in accordance with the drawings which give
information regarding the size, type and number of wires. Complete
all other small wiring in accordance with the relevant drawings.
3.4.3 Recommended Torque Settings
The following table gives recommended torque values for busbar and
connection joints when using standard ISO coarse thread, grade 8.8
hexagonal head bolts or screws with grade 8 nuts. They do not apply
when using proprietary locking screws or nuts (Wedlock, Nyloc,
etc.). These torque values are only applicable when both nut and
bolt, (or screws) are in a new clean dry, unlubricated condition with
standard plating finish. Lubricated threads may fail if torque values
much above those quoted are used. In general the figures equate to
good spanner tightness and are those normally obtained using
standard spanners.
SIZE RECOMMENDED TORQUE

Nm
M5 5.7
M6 7.9
M8 17
M10 28
M12 45
M16 91

M20 136
M24 215
3.5 EARTHING
The complete Distribution Board must be adequately bonded to earth

with solid copper strip, cable or substantial copper tape connected
between the Switchboard earth terminal and the substation earth bar.
When the system neutral to earth connection is an integral part of

the switchboard the standard arrangement is a removable link
between the neutral and earth busbar.
The main cubicle structures are effectively bonded to the earth bar.
3.6 CABLING
Cabling should be carried out in accordance with cable

manufacturer’s instructions ensuring that all contact surfaces are
clean and all bolts or screws properly tightened (see Section 3.4.3
for recommended torque).
Care must always be taken to ensure the maintenance of electrical

clearances. In particular care should be taken to avoid loose strands
of cable. Where terminal shrouds are provided they should be
securely fixed into their correct position, using screws provided.
Appropriate precautions must be taken at cable entry points into the

switchboard to ensure the IP. Degree of protection of the enclosure
is maintained.
4 COMMISSIONING
It is essential that all unauthorized personnel are kept clear of the

switchboard during operational checks or any tests involving high
voltages.
4.1 VISUAL INSPECTION
4.1.1 General
Check that the cubicles are assembled in the correct order as shown
on the general arrangement drawings. Check that main busbars
jointing, connections, earthing and cabling have been correctly

carried out and are complete.
Inspect the switchboard to ensure all insulation is clean and dry. If

there is any sign of dampness heaters should be used accordingly,
warm dry air applied for 2-3 hours will normally be sufficient.
WARNING: Excessive heat can damage some thermo-plastics.
If the Switchgear room is normally subject to dampness or

condensation suitable room heaters should be installed.
Check that cable entry cut-outs maintain the required degree of

protection of the enclosure and that all cable entries and gland plates
are correctly positioned and secure.
Check that there is adequate electrical clearance between conductors

and between conductors and earth, paying particular attention to
cable connections. Ensure that all screens, barriers and insulation
are in place and secure.
Check that all removable devices are correctly plugged in and

properly connected to their fixed contacts or the riser busbars as
appropriate.
Check that all power and auxiliary terminal blocks are correctly
placed.
Ensure that the interior of the cubicle is clean and all swarf, pieces
of cable or armour or any other foreign bodies, including tools, have
been removed. Excessive dust should be removed by vacuum
cleaning.
4.1.2 Fuses
Check that the correct type and size of fuselink has been fitted and
properly tightened on all fused equipment. The normal fuse rating to
be fitted is indicated on the appropriate wiring diagrams.
Check the device for any obvious signs of damage. Check the
mechanism operation of the device.
Check for any obvious signs of damage. Check for correct and free
operation of mechanisms and interlocks. Check that all necessary

shrouds, screens and barriers are properly fitted and secure.
4.2 MEGGER AND POWER FREQUENCY (DIELECTRIC) TESTS
Isolate all light current devices by isolating control circuit MCBs.

Disconnect voltage reference wires from electronic components, eg.
Protection Relays etc.
Megger the busbars, risers, etc. with a 1,000 volts megger between
phases, each phase and neutral to earth and record the readings. A
low reading will probably be due to dampness. However, if after
drying out readings are still unacceptable advice should be sought
from the manufacturers. Note that megger readings are dependent
upon the actual equipment concerned and on the size and complexity
of the switchboard and thus will differ within the product range.
When acceptable megger readings have been obtained a power

frequency test of 2.5kV for a minimum of 1 second may be applied.
A further megger test should give similar readings to those
previously recorded.
Switch ÒN' MCBs and replace all links and connections etc. and
carry out operational checks to confirm that the correct connections
have been made.
4.3 OPERATIONAL CHECKS
Check all circuit breakers, isolators etc. for correct and free
mechanical operation. Check auxiliary supplies for security and
stability.
Check all mechanical and electrical interlocks for correct

functioning. Note: Electrical interlocking schemes cannot be
properly checked and the switchgear should not be operated unless
all auxiliary circuit supplies are available and healthy.
Refer GA/SLD/Schematic drawings for various interlocking
schemes
Adjust/set all protection relays, trips and overload devices according

to the overall discrimination scheme and manufacturer's published
information.
Ensure that all protective devices, auxiliary and control equipment,

are in sound working order and their operation results in correct

operation of the equipment they control. Auxiliary tripping and
inter-tripping relays should be checked for correct operation by
energizing the appropriate circuits.
Secondary injection testing should be carried out on protective

devices as necessary.
4.4 ENERGIZING
The phase rotation of each incoming supply should be checked.

When there is more than one incoming supply, ensure that each
supply is correctly phased.
When all access covers have been secured in their correct positions
the incoming supplies may be made available.
Full operational checks should be carried out in line with normal

mode of operation to ensure the correct function and setting of each
device.
4 OPERATION
5.1 GENERAL
A regular programme of maintenance should be considered as a part

of the normal operating procedure.
Except for maintenance purposes, it is not normally necessary to

gain access to the interior of the switchboard or any device after
commissioning.
If circuit breakers trip, the cause must be ascertained and remedial

action taken before the device is put back into service
5.2 DIRECTION OF OPERATING HANDLES
Manually operated devices carry labels clearly indicating the normal

operating method.
Moulded case circuit breakers with linear motion have the direction
of switching indicated by label. The direction being dependent upon
the mounting method and position. For Moulded case circuit
breakers fitted with rotary handles, the direction of operation is

marked on the front side.
6. ROUTINE MAINTENANCE
6.1 GENERAL
For switchgear operating under normal service conditions, a

programme of maintenance should be carried out annually. For very
frequently operated equipment, intermediate maintenance intervals
of 6 or even 3 months should be considered. After short circuit
interruption, the cause must be ascertained and remedial action taken
before putting back into service. As soon as possible thereafter, the
routine maintenance programme should be carried out.
6.1.1 Safety
Before carrying out any maintenance work, ensure that the

equipment is isolated and safe and that all safety procedures and
safeguards are being applied (see Section 1.1).
6.1.2 Inspection
All connections and busbar joints should be checked for signs of

overheating. Any suspect joint face should be cleaned and properly
tightened (see Section 3.4.3). Plated contacts and connections
should be wiped or cleaned with metal polish if they appear black or
oxidized. The use of abrasives should not be necessary.
Check that there adequate clearance between phases and to earth and
that all mouldings, shrouds and barriers are in good condition and
properly fitted. Any accumulation of dust should be removed,
preferably with the aid of a vacuum cleaner.
6.1.3 Megger Test
Isolate all light current devices by isolating control MCBs. Remove

all main neutral links. Disconnect voltage reference wires from
electronic components, eg. Protection Relays etc. Megger the
busbars, risers, etc. with a 1,000 volt megger between phases, each
phase to neutral, each phase and neutral to earth. Significantly
reduced readings will probably be due to a build up of dust on, or
dampness of, the insulation. However if, after cleaning and/or
drying the insulation, readings are still unacceptable, advice should
be sought from the manufacturers.

When acceptable readings have been obtained switch ÒN' MCBs and
replace all links and connections etc. and carry out operational
checks to confirm that the correct connections have been made.
6.1.4 Operational Check
Carry out the operational checks detailed in Section 4.3
6.2 DEVICES
6.2.1 Instruments, Meters and Relays
Check the settings and adjust all necessary protection relays, trips
and overload devices. Ensure that all protective devices, auxiliary
and control equipment etc. are in sound working order and their
operation results in correct operation of the equipment they control.
These are factory sealed units and no maintenance is required other

than to check that all cable and connection joints are tight and that
all insulation shrouds, screens and barriers are in place and secure.
Check for any signs of damage or overheating. Check whether all

time delay and/or overload devices are correctly set. Check the
operation of any mechanical or electrical interlocks. Check all
connections are tight and all insulation, shrouds, screens and
barriers are in place and secure. Check all components for correct
operation
6.3 LUBRICATIONS
All devices, mechanisms and contact faces are oiled or greased

during manufacture as necessary. During normal life these
lubricants may evaporate or wiped off. Proper lubrication should be
carried out during routine maintenance as indicated. Excessive use
of lubricants particularly on light mechanisms is not advised and
surplus oil or grease should be wiped up.
7 TRANSPORTATION TO SITE:
7.1 Loading

7.1.1 Ensure that the equipments to be transported are ready for
lifting/transport.
7.1.2 Ensure that the area around the equipment to be lifted is clear of
obstacles.
7.1.3 Use suitably sized forklift or crane for loading the equipment
7.1.4 Ensure that the flooring of trailer used for transporting the
equipment is perfectly flat.
7.1.5 Load equipment on the trailer carefully on wooden blocks to avoid

slipping and with the use of suitably sized steel slings.
7.1.6 The equipment will be tied with strong belts to keep it in position
during transportation.
7.1.7 The trailer shall be driven slowly to site.
7.2 Unloading
7.2.1 The access to the site shall be checked during site survey and there
shall be no obstacles for the movement of the trailer/crane.
7.2.2 Release all belts used to hold equipment on trailer.
7.2.3 Unload equipments with suitably sized cranes/forklifts.
7.2.4 Equipments are then shifted to its final position in the substation by
means of 16mm diameter long rods. The equipment is rolled on those
rods.
********

DATE: Sep. 18, 2007
NO. KET-07110
Messrs .MITSUBISHI Electric Corp.
TECHNICAL DATA
Cable Installation Procedure
for Reference
Project: Kuwait 132kV CLZV
T.KOBAYASHI
Person in Charge
T.OHNO
Manager
Over Seas Engineering Group
Installation Engineering
Department
POWER CABLE ALLIANCE OF FURUKAWA & FUJIKURA, JAPAN

0
- CONTENTS -
1. HANDLING OF CABLE DRUM

(1) Transportation
(2) Loading and unloading of drums
(3) Storing and shifting of drums
(4) Caution & Drum handling Care
2. BASIC DESIGN OF CABLE PULLING
2-1. Permissible parameters for Cable pulling

(1) Maximum permissible pulling tension
(2) Maximum permissible cable side wall pressure
(3) Maximum bending radius
(4) Diameter of road crossing duct
2-2. Design of Cable Pulling

(1) Formula of cable pulling tension
(2) Typical coefficient of friction
(3) Pulling direction
3. CABLE LAYING
3-1. Cable laying in trench/pit
3-2. Procedure of cable pulling

(1) Inspection the cable route condition
(2) Checking installation of the pipe ducts and cleaning them
(3) Setting cable pulling winch and drum of cable pulling wire
(4) Setting the cable drum on cable drum jack
(5) Inspection the surface of cable
(6) Setting cable rollers/curve rollers
(7) Setting guide rollers with supporting facilities
(8) Setting portable telephone along the cable route
(9) Laying of cable pulling wire in cable route
(10) Connecting the cable pulling wire to cable
(11) Cable pulling
1
1. HANDLING OF CABLE DRUM
(1) Transportation
The cable wound on the drum is to be carefully transported by lorry or trailer-truck.
The care shall be given so as to prevent the cable drum from having any injurious
shock during transportation.
The cable drum is to be tightly settled on the lorry/trailer-truck with strong ropes and
wooden stoppers are to be put below the drum.
The cable drum shall not be laid flat at anytime.
(2) Loading and unloading of drums

The cable drum is to be taken up and down with a crane having suitable capacity.
Suitable slings and steel shaft which are enough to bear weight of the cable drum are to
be used.
(3) Storing and shifting of drums

When the cable drum is rotated or shifted, it should be moved according to the arrow
mark printed on the side surface of drum, so as to avoid looseness of the cable winding.
After the cable drums are settled in the position, wooden stoppers are to be put below
them at all times, in order to avoid movement of them.
Detail procedure of cable drum handling is shown in “Cable reel handling” attached.
2
2. BASIC DESIGN OF CABLE PULLING
2-1. Permissible Parameters for Cable Pulling

(1) Maximum Permissible pulling tension
(Conductor/Pulling eye – Cable pulling)
Maximum permissible pulling tension of cable is calculated by the following formulas.
(Formula of copper conductor cable)

Maximum permissible pulling tension = (Conductor area in mm2 )×７kg/mm2
(For example)
Copper conductor size: 240 mm2
The maximum pulling tension is 240 mm2×７kg/mm2 = 1,680 kg
Prior to the actual cable pulling, pulling tension is calculated and final pulling tension
is certified less than the maximum permissible pulling tension.
(2) Maximum permissible cable sidewall pressure

Sidewall pressure for cables of bending part shall be applied smaller than 500kg/m
generally as defined the following formula.
T
P=
R
Where : P = Sidewall pressure (kg/m)
: T = Pulling tension at exit from bend (kg)
: R = Bending radius (m)
(3) Minimum bending radius

Minimum bending radius of cable is calculated by the following formulas.
Positioning : 15 x Average of overall metallic sheath diameter (Ds)

Laying condition : 22.5 x Average of overall metallic sheath diameter (Ds)
(For example)
Metallic sheath diameter (Ds): 108 mm
Minimum bending radius of laying condition is 108 mm×22.5 = 2,430mm
3
(4) Diameter of road crossing duct
Diameter of road crossing duct is designed according to the following formula.
One (1) cable should be installed in one (1) road crossing duct.
D > 1.3d moreover
D > d + 30 (mm) where : D : lnner diameter of duct. (mm)
d : Overall diameter of cable.(mm)
(For example)
1.3d = 1.3 × 112 = 145.6, d + 30 = 112 + 30 = 142, therefore, D > 146 mm
2-2. Calculation of Cable Pulling tension

(1) Formula of cable pulling tension
CONDITION CALCULATION FORMULA (kg)
T=μ W L
T= W L ( μ cos α + sin α ) …up
T= W L ( μ cos α - sin α ) …down
T2= T1 eμθ
T2= T1 eμθ + WR { ( 1 - μ2 ) sin θ + 2 μ ( eμθ - cos θ ) }

1+ μ2
WR
T2= T1 eμθ + 1+ μ2 { 2 μ sin θ − ( 1 − μ2 )( eμθ - cos θ ) }
WR
μθ
T2= T1 e − 1+ μ2 { ( 1 - μ2 ) sin θ + 2 μ ( eμθ - cos θ ) }
4
WR
T2= T1 eμθ − 1+ μ2 { 2 μ sin θ − ( 1 − μ2 )( eμθ - cos θ ) }
W R sin α
T2= T1 eμθ + { ( 1 - μ2 ) sin θ + 2 μ ( eμθ - cos θ ) }
1+ μ2
W R sin α
T2= T1 eμθ − { 2 μ sin θ + ( 1 − μ2 )( eμθ - cos θ ) }
1+ μ2
W R sin α
T2= T1 eμθ − { ( 1 - μ2 ) sin θ + 2 μ ( eμθ - cos θ ) }
1+ μ2
W R sin α
μθ
T2= T1 e − 1+ μ2 { 2 μ sin θ − ( 1 + μ2 )( eμθ - cos θ ) }
Where : T = Pulling tension (kg)

μ = Coefficient of friction
Ｗ = Weight of cable per meter (kg/m)
Ｌ = Cable length (m)
θ１= Tilt angle (radian)
θ = Angle of bend (radian)
T１ = Pulling tension to entrance to bend (kg)
T２ = Pulling tension at exit from bend (kg)
Ｒ = Bending radius (m)
5
(2) Typical coefficient of friction
Pulling condition for duct material Coefficient of friction
Roller 0.1－0.2
P.V.C pipe without lubricant 0.3－0.5
P.V.C pipe with lubricant 0.2－0.3
Asbestos cement pipe without lubricant 0.5－0.7
Asbestos cement pipe with lubricant 0.3－0.4
(3) Pulling direction

Pulling direction should be decided so as to be less the pulling tension and sidewall
pressure during cable pulling.
One of the ends of the cable route is selected for setting of cable drum and the other is
for the winch according to the basic design of cable pulling and to add to the situation
of cable route as the space for setting of cable drum, etc.
6
3. CABLE LAYING
3-1. CABLE LAYING IN TRENCH/PIT

Typical procedure for the cable laying work in trench/pit/ is shown on following scheme.
And, typical situation for cable laying is shown on drawing
Winch side Trench/pit& Cable drum side

pipe duct
Setting cable pulling Inspection the cable Transportation of cable

winch and drum of route condition drum and stting it on
cable pulling wire Cleaning the pipe duct cable drum jack
Remove wooden
Setting cable rollers
battens from cable
/curve rollers in
trench/pit/
Inspection the surface
of cable
Laying cable pulling
wire in trench/pit/
Setting guide rollers
& pipe duct
with supporting
facilities
Setting portable telephone along the

cable route
Connecting the cable pulling wire to

cable through a swivel and a pulling
eye hook
Pulling cable
7
3-2. PROCEDURE OF CABLE PULLING
(1) Inspection the cable route condition
Before the cable pulling work commences, the whole trench/pit is to be inspected.
In case of the direct, buried type trench, the bedding sand for cables should be filled
smoothly and any objects as the gravel which has fallen from the ground to the
surface of bedding sand should be removed.
(2) Checking installation of the pipe ducts and cleaning them

Before the cable pulling work commences, the pipe ducts for road crossing, etc. are to
be checked to ensure that they are correctly aligned and to be cleaned.
The cleaning brush having suitable size for pipe duct should be passed through the
pipe ducts and removed any obstacles in the pipe ducts.
(3) Setting cable pulling winch and drum of cable pulling wire
The cable pulling winch is to be fixed firmly so that it can stand against the pulling
force.
The winch is to be capable of changeable pulling speed in the range of 0-10meter per
minute.
The winch should be equipped with a tension meter so as to control the cable pulling
tension.
And the drum of cable pulling wire should be settled at the appropriate position in
order to roll up the wire rope easily.
(4) Setting the cable drum on cable drum jack

The cable drum transported to the construction site is to be set on the cable drum jack.
The cable drum and the cable drum jack should be settled at the appropriate position
for cable pulling.
(5) Inspection the surface of cable and checking of pulling head

Outer surface of the cable is to be inspected visually for scratches and make sure that
the pulling head is free any crack before and after laying work.
(6) Setting cable rollers/curve rollers

Cable rollers are to be disposed at proper position into the trench/pit.
The intervals of the rollers are to be kept approx.2m
The rollers are to be maintained so as to rotate smoothly.
If the cable is planned to be pulled through the curvature, curve rollers should be
settled a proper positions in order to keep the suitable cable bending radius.
8
(7) Setting guide rollers with supporting facilities
The cable guide rollers are settled at the appropriate position between cable drum
And trench/pit/tunnel in order to lead the cable from cable drum to trench/pit
smoothly.
(8) Setting portable telephone along the cable route

After the facilities and the equipment were properly set, the portable telephones are
to be located on the drum- side, leading end of the cable and the winch- side.
They are utilized to control the cable pulling speed and other communication.
(9) Laying of cable pulling wire in cable route

The cable pulling wire should have 4 times as much safety factor for calculated
maximum value of pulling tension.
It is important that the wire is to be handled in such a manner that it is not twisted,
untwisted or kinked.
(10) Connecting the cable pulling wire to cable

Pulling eye hook that is fixed at top of the cable is connected to the cable pulling wire
through a swivel and shackles.
A swivel and shackles should have the proper size for cable pulling.
(11) Cable pulling

Cable pulling is to be started gradually.
A watch man is to be located to observe the leading end of the cable. Who walks along
the cable being pulled.
The rotating speed of the drum is to be corresponding to that of the pulling speed.
If necessary, the rotating speed is controlled with a simple wooden brake.
The pulling speed must be kept at suitably.
During the cable pulling, indication of the tension meter is to be observed.
9
DATE: Sep. 18, 2007
NO. KET-07111
Messrs .MITSUBISHI ELECTRIC Corp.
TECHNICAL DATA
Instruction Manual of SF6 Gas and Oil immersed sealing end
for Reference
Project: Kuwait 132kV CLZV
T.KOBAYASHI
Person in Charge
T.OHNO
Manager
Over Seas Engineering Group
Installation Engineering
Department
POWER CABLE ALLIANCE OF FURUKAWA & FUJIKURA, JAPAN

2/11
KET-07111
Instruction Manual of SF6 Gas and Oil immersed sealing end

for
132kV 1×800mm2 XLPE cable
1. General
This instruction describes the "general guidance of the terminating method of SF6 gas
immersed sealing end and Oil immersed sealing end for 132kV 1×240mm2 XLPE cables"
limited use of approved jointers who have been qualified by VISCAS/Fujikura as 275kV
XLPE cable jointer or equivalent jointer.
It must be noted however that the observance and compliance with this instruction by jointers
in their terminating work shall not mean to institute the guarantee for the satisfactory
completion of the termination. Because the termination technique, experiences, standard of
skill and other capabilities of the jointer will influence the result of his termination work.
Before the commencement of the termination work, all parts, tools, special equipment, etc.
shall be well prepared and be in proper conditions for the use.
Ref. Specification No: ＊＊＊＊＊

SF6 Gas Immersed Sealing End (IEC TYPE)
for 132kV 1×240mm2 XLPE cable
2. Conditions for assembling work

1. Weather condition
If the relative humidity prior to or during the course of works is 80% or more, air conditioners and
de-humidifiers shall be employed to reduce the humidity level in the work area..
2. Environmental condition
It is required that the assembling work shall be carried out under the clean circumstances using
tent, plastic sheet, etc.
3. Sealing “O”ring gaskets

Keep the “O”ring gaskets and the grooves (gasket-way) clean. And lubricate the gaskets and their
grooves with silicone grease thinly to prevent damage to them.
4. Tightening Torque for bolts and nuts

M8 ------- 100kg-cm (9.8N･m)
M10 ------- 190kg-cm (18.6N･m)
M12 ------- 330kg-cm (32.3N･m)
M16 ------- 600kg-cm (58.8N･m)
5. Special attention
Before the termination start, the cable box and its base plate of GIS and Transformer should be
remove by the person in charge of GIS or Transformer work.
1/7
KET-07111
3. Flowchart of terminating work
The terminating work shall be carried out in accordance with the following procedure.
1. Preparation
2. Temporary cutting
3. Removing metallic sheath.
4. Cutting cable
5. Removing outer semi-conductive layer.
6. Exposing conductor
7. Sanding out cable insulation
8. Compression connecting rod
9. Applying ACP tape
10. Applying shielding tape around
11. Setting stress relief cone
12. Assembling epoxy bushing
13. Assembling rod clamp
14. Assembling lower sleeve
15. Sealing lower sleeve
16. Fixing to GIS or Transformer case
17. Assembling the shield ring
18. Earthing
2/7
KET-07111
4. Detail of terminating work
1. Preparation
1) Measure the final cutting line from Base plate for GIS. All measurements are based on
a final cutting line.
2) Locate the cable on its final position and make it straightened with chain blocks and a
cable bender.
3) Mark the cable cutting line.
2. Temporary cutting
1) Cut the cable leaving excess length of approx. 300mm from the final cutting line.
3. Removing metallic sheath.

1) Remove serving and metallic sheath, leaving excess length of approx. 300mm from the
final cutting line.
4. Cutting cable
1) Cut the cable at final cutting line squarely.
2) Lower sleeve, O-rings, stud bolts, spring loaded plate, sprig and shafts, push-up ring,
shall be placed along cable is in the correct direction and order.
5. Removing outer semi-conductive layer.

1) Apply a PVC tape at specified length from the cable cutting point for marking the end
of outer semi- conductive layer to be removed.
2) Check the diameter of the cable, at least three points between the outer
semi-conductive layer to be removed. Take notes the smallest diameter.
3) Remove the outer semi-conductive layer until marking point. During removing, fix the
cable properly with ropes and protection for the cable.
<in case of using glass plate only>
a. Remove the outer semi-conductive layer with edge of glass plate smoothly and thinly.
b. Remove the stripped mark with glass plate as smooth as possible.
<in case of using striping tool and glass plate>
c. Adjust four rollers of the stripper and set it on the cable end. Rotate it a few times and
ensure that always four rollers are touching the cable and the stripper can be turned
smoothly.
d. Adjust the blade of the stripper in order to strip the outer semi-conductive layer and it
should be stripped thinly, 0.1 - 0.5 mm. and smoothly.
e. After reaching the stripping point, slide back the blade of the stripper, and then slide
back the two rollers opposite of the blade. Then take off the stripper from the cable by
paying attention not to injure the cable by blade or rollers.
f. Remove the stripped mark with glass plate as smooth as possible.
Note
1) Do not strip beyond the marking.
2) Stripping must be done more than two times.
3) If rotation is not smooth, it causes over stripping thickly.
4) Measure the diameter of the cable at three points (P. Q. R) where the outer
semi-conductive layer removed, and compare this dimension with specified values.
5) Repeat the work 3)~4) until the diameter get in the range above. Final finishing shall be
stripped by glass plate to avoid over stripping thickly.
6) Make smooth taper a boundary at the edge of the outer semi-conductive layer with glass
plates.
3/7
KET-07111
6. Exposing conductor
1) Mark the exposed line of the cable insulation with PVC tape.
2) Adjust the blade of the stripper in order to expose the XLPE insulation and it should be
exposed.
3) Shall be exposed following procedure 4)~6), if no use the stripper.
4) Make a deep cut about 90% the XLPE insulation circumference of exposed line with saw.
Note
1) Do not injure the cable conductor.
Exposed line
PVC
5) Rubbing and cutting the XLPE insulation with string until reach the conductor.
PVC String
PVC
6) Pull out the cable insulation piece by hammer and minus screwdriver while protecting the
cable insulation.
7) Chamfer the edge of XLPE insulation (C2~C5) using a glass plate after exposing.
7. Sanding out cable insulation

1) Sand out the insulation with sand papers below.
#120 → #240 → #320 → #400 → #600
2) Sand out more than ten times 4-ways for each number of sand papers, and continue until the
trace of the former number of sand paper disappeared.
Sand paper
3) Sand out the cylindrical portion of XLPE insulation at first after protection on connecting
rod and tapered outer semi-conductive layer with protection materials.
4) 2nd step, sand out the pencilled portion of XLPE insulation after protection on cylindrical
portion of XLPE insulation with protection materials.
5) 3rd step, sand out the tapered outer semi-conductive layer.
6) Measure and Record the diameter of the cable at three points (P. Q. R) where the outer
semi-conductive layer removed, and compare this dimension with specified values.
7) Clean the XLPE insulation sufficiently with lint free tissue papers and solvent approved.
Check and confirm there is no scratch and dust.
Note
1) Do not sand out XLPE insulation using the sand papers, which sanded out the outer
semi-conductive layer.
2) Cleaning direction should be only from the cable insulation to the semi-conductive
layer.
3) Cleaning times is four times.
8. Compression connecting rod

4/7
KET-07111
1) Protect the XLPE insulation and the outer semi-conductive layer for protection materials.*1
See ; Protection materials*1 --- insulation tape (FB-W tape), polyester wrap, etc.
2) Re-straighten the cable.
3) Set the connecting rod on the conductor and compress it with the dies.
4) After compressing, the surface of the connecting rod shall be made smooth with file.
Note
1) Compress the connecting rod straight against the cable.
2) Do not injure the cable while smoothing the connecting rod
3) Compress the connecting rod before inserting the premolded stress relief cone.
9. Applying ACP tape

1) Clean the cable surface at portion of applied ACP tape layer.
2) Mark the semi-conductive painting area using the adhesive polyester tape.
3) Paint the semi-conductive paint smoothly with the brush provided
4) Re-paint the semi-conductive paint after dried it for about 10min.
5) Remove the adhesive polyester tape applied for marking.
6) Apply 1 turn of ACP tape with 1/2 lap on a point 5mm from the both edges of the
semi-conductive paint from the cable outer semi-conductive layer side.
Note
1) Cleaning direction should be only from the cable insulation to the semi-conductive
layer.
2) Make straight the edge of ACP tape at the turning point.
10. Applying shielding tape around

1) Apply the tapes on the cable outer semi-conductive layer between the applied ACP tape
layer and the semi-conductive cloth tape.
2) Apply 1 layer of C tape with 1/2 lap from a point 10mm from the edge of ACP tape, to end of
metallic sheath.
3) Apply 1 turn of lead tape with 1/2 lap from a point 10mm from the edge of C tape, to end of
metallic sheath and to beginning point.
4) Place 2 pieces of 8mm2 tinned copper braid with longitudinally, and bind & solder them
with 5.5mm2 tinned copper braid on semi-conductive tape layer and with tinned copper wire
on metallic sheath.
5) Apply 1 layer of FB-W tape with 1/2 lap from a point 10mm from the edge of C tape, to an
overlapped point 30mm from end of metallic sheath.
11. Setting stress relief cone

1) Remove the all protection materials on the cable.
2) Clean the connecting rod.
3) Clean the inner surface of stress relief cone and XLPE insulation with lint free tissue paper
and solvent approved
4) Spread with silicon oil on the cable insulation and inner surface of the stress relief cone.
5) Insert the stress relief cone.
6) Slide down the stress relief cone on the cable by hands slowly and carefully until its lower
end goes over the top of the ACP tape for about 50mm.
Note
1) Before inserting stress relief cone, re-confirm that all parts placed along the cable is
in the correct direction and order.
2) Wiping direction should be only from the insulation side to the semi-conductive
side.
3) When the stress relief cone reaches the ACP tape, rotate it to same direction with
that of the ACP tape, and slide down carefully.
5/7
KET-07111
12. Assembling epoxy bushing

1) Clean the epoxy bushing and stop ring. Check and confirm there is no scratch, dust and
moisture which affect the quality of the sealing end.
2) Clean the outer surface of the stress relief cone and cable insulation. Check and confirm
there is no scratch, dust and moisture which affect the quality of the sealing end.
3) Clean the connecting rod and spread silicon grease on the O-ring and place it on the
connecting rod.
4) Spread silicone oil uniformly on the outer surface of the stress relief cone which touches the
inner surface of the epoxy bushing.
5) Insert the stop ring.
6) Insert the epoxy bushing onto the cable.
Note
1) Do not injure the cable and stress relief cone while inserting the epoxy bushing.
2) Do not injure the epoxy bushing by connecting rod.
13. Assembling rod clamp

1) Clean the connecting rod, fixing nut, conductor fixing metal, upper metal, and O-rings.
2) Spread with silicon grease on the O-ring and place it on the connecting rod.
3) After placed O-ring, fix the upper metal.
4) Confirm the final setting point of adjusted connecting rod, and fix it with conductor fixing
metal, and fixing nut.
14. Assembling lower sleeve

1) Slide up the stress relief cone by pushing up the push up ring until upper part of the stress
relief cone touches the inner surface of the epoxy bushing.
2) Fix the 2 pcs of 8mm2 tinned copper braid bound & soldered on previous progress to the
stud bolt of push-up ring.
3) Clean the O-ring and the bottom of epoxy bushing.
4) Spread with silicone grease on the O-ring and groove of lower sleeve for place it
5) After placed O-ring, fix the lower sleeve.
6) Insert rubber sheet between the lower sleeve and the metallic sheath.
7) Lay down 8 pcs of tinned copper braid from the lower sleeve to the metallic sheath. Bind and
solder them with tinned copper wire.
Note
1) Do not injure the cable and stress relief cone while sliding up the push-up ring etc.
2) Measure and Record the distance between epoxy bushing and push-up ring.
15. Sealing lower sleeve

1) Remove conductive paint on the cable serving more than 130mm from the end of the serving
using sandpaper or glass plate.
2) Seal with below tapes between lower sleeve and cable to avoid soaking into moisture, dust,
etc.
FB-W tape ------------- Fill the gap of lower sleeve and cable
Glass tape with epoxy resin ------------- 5 layers with ½ lapped
FB-W tape ------------- 4 layers with ½ lapped
PVC tape ------------- 2 layers with ½ lapped
16. Fixing to GIS or Transformer case

1) Fix the sealing end to the base plate of the GIS or Transformer with the flange, packing,
bolts and gasket.
6/7
KET-07111
2) The method of rising up sealing end into the cable box of the GIS or Transformer should be
decided at job site according to the actual situation.
17. Assembling the shield ring

1) Confirm the final setting point of adjusted terminal lug, and fix it to connecting rod with
bolt.
18. Earthing
1) Connect earthing cable to the earthing terminal of the lower sleeve for earthing.
7/7
INSTALLATION & MAINTENANCE
INSTRUCTIONS
FOR
CONTROL PANEL, RELAY PANEL,
PILOT MARSHALLING CABINET AND
TELEMETRY TERMINAL TRANSFER CABINET
PURCHASER : MINIST RY OF ENERGY (ELECT RICIT Y & WAT ER),

KUWAIT .
CONT RACT OR : MIT SUBISHI ELECT RIC CORPORAT ION
CONT RACT NO. : ME/EW/C/3377-2005/2006 – SAAD AL ABDULLA ‘A’

– SAAD AL ABDULLA ‘B’
– SAAD AL ABDULLA ‘C’
– SAAD AL ABDULLA ‘D’
July 2008 (Rev.0) Publication No. AIM/08/54
I:\USERS\DESIGN\FILES\KUWAIT\MEW\EO290\MITSUBISHI_MANUAL.DOC Page 1 of 17
CONTENTS
1. SAFETY PRECAUTIONS
1.1 General
1.2 Emergency Pro cedures
1.3 Handling
1.4 Installatio n and Commissio ning
1.5 Maintenance
2. DESCRIPTION OF EQUIPMENT
3. INSTALLATION
3.1 Handling
3.2 Sto rage
3.3 Erect ion
3.3. 1 General
3.3.2 Framework Joint ing
3.4 Co nnect ions
3.4. 1 Eart h Busbars
3.4.2 Seco ndary Connect io ns
3.4.3 Recommended To rque Sett ings
3.5 Eart hing
3.6 Cabling
4. COMM ISSIONING
4.1 Visual Inspection
4.1. 1 General
4.1. 2 Fuses
4.1.3 Miniature Circuit Breakers
4.1.4 Contact o r, Relay and General Panel Equipment
4.2 Megger & Flash Test s
4.3 Operat io nal Checks
4.4 Energizing
5. OPERATION
5.1 General
5.2 Directio n o f Operating Handles
6.1 General
6.1.1 Safety
6.1.2 Inspect io n
6.1.3 Megger Tests
6.1.4 Operat io nal Checks
6.2 Devices
6.2.1 Inst rument s, Meters and Relays
6.2.2 Miniature Circuit Breakers
6.2.3 Contact o r, Relay and General Panel Equipment s
7. TRANSPORTATION TO SITE
7.1 Lo ading
7.2 Unloading
8. ATTACHMENT
8.1 Annexure-1: List o f devices used in contr ol and relay panels.
1.1 GENERAL
It is t he dut y o f all perso ns, direct ly o r indirect ly asso ciated wit h t he

installation, contro l, operation or maintenance of the equipment to
eliminate o r minimize any risks t o healt h o r safety.
All persons operat ing or working on t he equipment must be competent

and be aware of any dangers, which may arise during normal operation.
Too ls must not be used to gain access to any part without first referring
t o t he appro priate instructions or drawings. Covers, doo rs or screens
carrying a warning o f live equipment must not be removed wit hout
ensuring t hat t he equipment is first made dead.
1.2 EMERGENCY PROCEDURES
Should an abnor mal condit ion arise, eit her in t he swit chgear or it s
associated equipment and cables, and t hen t he fo llo wing procedure must
be adopt ed:
a) Immediately isolate fro m t he supply any area o f fault .
b) Should a fault have o ccurred in o r adjacent t o an incoming

t ransfo rmer panel, t he asso ciated circuit breaker must also be
t ripped.
c) In case of fire, t he mains and standby supplies must be isolated.
d) Do not , under any circumstances, use wat er t o put out a fire in or

aro und electr ical equipment .
e) For perso nal injury o r electric sho ck, seek immediate medical advice
and attention.
f) Aft er a fault and prior t o reinstatement , equipment must always be

checked by a co mpet ent person o nly, t o ascert ain t he cause and any
remedial act io n t aken. As soo n as possible, t hereaft er t he ro utine
maint enance pro gramme sho uld be carried o ut . Only Aut ho rized
personnel must work on H.V./L.V. equipment .
1.3 HANDLING
Each panel is fit t ed wit h lift ing eyes or lift ing hooks t o assist handling.
Lift ing arrangements must be such t hat t he lo ad is carried evenly
between all t he eyes/hooks provided and t hat as far as po ssible inclined
lo ading is avo ided. It is reco mmended t hat spreader frames must be
used t o achieve t his since t he safe wo rking lo ad o f t he eyebo lt is
significant ly reduced when inclined lo ading is applied.
When ro llers are used t o assist handling a lo ad bearing plat e must be

po sit ioned between t he panel base and t he ro llers. Special care must
always be t aken t o prevent t he panel t o ppling o ver when t he ro llers are
emplo yed, part icularly on uneven or sloping surfaces.
The panel must always be t ranspo rt ed t he right way up. When packed
t he case markings indicat e t he correct posit io ns.
1.4 INSTALLATION AND COMMISSIONING
Information on the design, construction and installation of equipment to

ensure t hat so far as is reaso nably pract icable it is safe and wit hout risk
t o healt h when pro perly used may be fo und in:
a) Relevant Brit ish St andard Specifications and Codes of Pract ice.
b) Ministry of Electricit y & Water, Kuwait specifications and

regulatio ns.
c) Relevant catalogues and Pro duct Data Sheets of t he equipment

manufacturers.
The equipment must be installed o r commissio ned by o r under t he

supervision of compet ent persons in accordance wit h MEW Regulations,
St atut ory Requirement s and Inst ruct ions specifically advised by t he
manufactur er.
1.5 MAINTENANCE
Befo re carrying o ut any maint enance work ensure t hat t he equipment is

isolated and safe. Consult manufacturer's relevant manual covering
maint enance and/o r service of t he part icular equipment before
pro ceeding furt her. The incoming supply must be isolated by lo cking o ff
supplies fro m o t her panel. The isolat io n sho uld be checked wit h
suit able reliable t est equipment .
While all incoming supplies may have been isolat ed, cert ain
auxiliary/co nt ro l supplies may still be "live", e.g. DC t ripping supplies
from a battery unit.
Alt hough means of isolat ion is pro vided while wo rking on t he load side
of devices by opening or t ripping t he respective circuit device, measures
must be t aken t o prevent unint ended re-closure. E. g. Padlocking in t he
o ff po sit io n.
These instruct ions cover cont ro l and relay panel, pilot marshalling
cabinet bo x and Telemet ry t erminal t ransfer cabinet and similar
equipment s.
Info rmatio n regarding size, layo ut , arrangement o r devices, rat ings, etc.
is given o n t he general arr angement drawings and t he circuit diagrams
supplied wit h t he equipment as part of cont ract . Infor mation regarding
t ype and make o f devices installed in t he cont ro l and relay panels is
given in annexure-1.
3 INSTALLATION
3.1 HANDLING
Panels may be lift ed using eyebo lt s o r ho o ks pro vided o r mano euvred

into position on rollers with a load bearing plate between the base of the
panel and t he ro llers. The panels must always be t ranspo rt ed t he right
way up. When packed t he case markings indicate t he correct po sit io n.
See also Sect ion 1.3 regarding safety precautions.
3.2 STORAGE
The equipment must always be sto red indo o rs in dry, clean condit io ns,
free of cont aminating or corro sive atmospheres. It should be sto red in
an upr ight po sit ion and where po ssible-swit ching devices should be
placed in t he "On" po sit ion.
3.3 ERECTION
3.3.1 GENERAL
The Cont ro l Panel must be erect ed on a level and even surface. If

necessary shims o r packers sho uld be used between t he panel base and
t he floo r t o achieve correct alignment . It is recommended t hat a
minimum of 1 meter clear space be made available all aro und t he floor
mount ing panel board for ease of operation/maint enance.
When panels have been split for t ransport check t he general arr angement
drawing t o ensure t hat t hey are erect ed in t he correct sequence and t hat
all panels are present . Each panel has pro visio n fo r fo undat io ns bo lt s
and has fixings securing it t o t he adjacent panel. The frame fixing
screws are supplied. The foundat ion bolt s should not be t ight ened down
unt il t he panel frame jo int ing bolt s are correctly fit t ed.
3.3.2 FRAMEWORK JOINTING
Each framework is secured t o t he adjacent frame wit h screws passing

t hro ugh clearance holes in t he framework of t he panels.
3.4 CONNECTIONS
3.4.1 EARTH BUSBARS
The eart h busbar o f t he adjacent panel is jo inted wit h t he fishplat es,

bolt s, nuts and washers pro vided wit h t he panel. Ensure t hat t he jo ints
are properly t ight ened.
3.4.2 SECONDARY CONNECTIONS
Det ails o f seco ndary wiring and co nnect io ns are given o n t he relevant
schemat ic diagrams. All bus wires must be t erminat ed in accordance
wit h t he drawings which give informat ion regarding t he size, t ype and
number of wires. Complete all ot her small wiring in accor dance wit h
t he relevant drawings.
3.4.3 RECOMM ENDED TORQUE SETTINGS
The fo llo wing t able gives reco mmended t o rque values fo r busbar and
co nnect io n jo int s when using standard ISO co arse t hread, grade 8.8
hexagonal head bolt s or screws wit h grade 8 nut s. They do not apply
when using pro prietary lo cking screws o r nuts (Wedlo ck, Nylo c, etc.).
These t o rque values are o nly applicable when bot h nut and bolt , (o r
screws) are in a new clean dry, unlubricat ed co ndit ion wit h standard
plating finish. Lubricated t hreads may fail if t o rque values much abo ve
t ho se quot ed are used. In general t he figures equat e t o goo d spanner
t ightness and are t ho se no rmally o bt ained using standard spanners.
SIZE RECOMM ENDED TORQUE

Nm
M5 5.7
M6 7.9
M8 17
M10 28
M12 45
M16 91
M20 136
M24 215
3.5 EARTHING
The complete Contro l Panel or Pilot marshalling cabinet or Telemetry

t erminal t ransfer cabinet must be adequat ely bonded t o eart h wit h solid
copper strip o r cable o r substant ial copper t ape connect ed between t he
Equipment eart h t erminal and substat ion eart h bar.
3.6 CABLING
Cabling sho uld be carried o ut in accor dance wit h cable manufacturers

instruct io ns ensuring t hat all contact surfaces are clean and all bo lt s o r
screws properly t ight ened (see Sect ion 3.4.3 for recommended t orque).
Care must always be t aken t o ensure t he maint enance of electrical

clearances. In particular care sho uld be t aken t o avo id lo o se strands o f
cable. Where t erminal shro uds are provided t hey should be securely
fixed int o t heir correct posit ion, using screws provided.
Appropriate precautions must be t aken at cable ent ry point s int o t he

panel t o ensure t he IP. Degree of prot ect ion of t he enclosure is
maint ained.
4 COMMISSIONING
It is essent ial t hat all unauthorized personnel are kept clear of t he

Contro l panel/ Pilo t marshalling cabinet / Telemetry t erminal t ransfer
cabinet during o perat io nal checks o r any t ests invo lving high vo lt ages.
4.1 VISUAL INSPECTION
4.1.1 GENERAL
Check t hat t he panels are assembled in t he correct o rder as sho wn o n

t he general arrangement drawings. Check t hat co nnect io ns, eart hing and
cabling have been cor rectly carried o ut and are complete.
Inspect t he cont ro l panel t o ensure all insulatio n is clean and dry. If

t here is any sign of dampness heaters should be used accordingly, warm
dry air applied for 2-3 hours will normally be sufficient .
WARNING: Excessive heat can damage some t hermo -plastics.
If t he Swit ch ro om is nor mally subject t o dampness or condensat ion

suit able ro om heaters should be installed.
Check t hat cable ent ry cut-o uts maint ain t he required degree of
prot ect io n o f t he enclosure and t hat all cable ent ries and gland plates
are correct ly posit ioned and secure.
Check t hat t here is adequate electrical clearance between conducto rs

and between conduct ors and eart h, paying particular att ent ion t o cable
connect ions. Ensure t hat all screens, barriers and insulation are in place
and secure.
Check t hat all removable devices are correctly plugged in and pro perly
connect ed.
Ensure t hat t he int erio r o f t he panel is clean and all swarf, pieces o f
cable o r Armo ur o r any o t her fo reign bodies, including t o o ls, have been
remo ved. Excessive dust sho uld be remo ved by vacuum cleaning.
4.1.2 FUSES
Check t hat t he co rr ect t ype and size of fuselink has been fit t ed and
properly tightened on all fused equipment. The normal fuse rating to be
fit t ed is indicated o n t he appropriate wiring diagrams.
4.1.3 MINIATURE CIRCUIT BREAK ERS
Check t he device for any obvious signs of damage. Check t he device’s

mechanism of operat ion.
4.1.4 CONTACTOR, RELAY AND GENERAL PANEL EQUIPMENTS
Check fo r any o bvio us signs o f damage. Check fo r correct and free

o perat io n o f mechanisms and int erlo cks. Check t hat all necessary
shro uds, screens and barriers are pro perly fit t ed and secure.
4.2 MEGGER AND FLASH TESTS
Isolate all light current devices by isolating contr ol MCBs. Remove all
main neut ral links. Disconnect vo lt age reference wires fro m electro nic
component s, e.g. Pro t ect ion Relays etc. Wit h 1000-volt megger check
IR between phases, each phase t o neutral, each phase and neutral t o
earth, DC circuits to earth. Significantly reduced readings will probably
be due t o a build up of dust on, or dampness of, t he insulation.
However if, aft er cleaning and/o r drying t he insulation, readings are still
unacceptable advice sho uld be sought fro m t he manufact urer s.
When accept able readings have been o btained swit ch ÒN' MCBs and
replace all links and connectio ns et c. and carry o ut o perat io nal checks
t o confirm t hat t he correct connect ions have been made.
4.3 OPERATIONAL CHECKS
Check all equipment s fo r correct and free mechanical o perat io n. Check

auxiliary supplies fo r securit y and stabilit y.
Check all mechanical and electrical interlocks for correct

functioning. Not e: Electrical int erlocking schemes cannot be pro perly
checked and t he swit chgear should not be operat ed unless all auxiliary
circuit supplies are available and healt hy.
Refer GA/SLD/Schematic drawings for various interlocking schemes
Adjust or set all prot ect ion relays, t rips and overload devices according
t o t he overall discriminat ion scheme and manufacturer's published
info rmat ion.
Ensure t hat all pro t ective devices, auxiliary and cont ro l equipment , are
in sound working or der and t heir operation result s in correct operation
of t he equipment t hey contr ol. Auxiliary t ripping and int er-t ripping
relays should be checked for co rrect operat ion by energizing t he
appro priate circuit s.
Secondary inject ion t est ing should be carried out on prot ect ive devices
as necessary.
4.4 ENERGIZING
The phase ro t at io n o f each incoming supply should be checked. When

t here is mo re t han o ne incoming supply, ensure t hat each supply is
correct ly phased.
When all access co vers have been secur ed in t heir co rr ect po sit io ns t he
incoming supplies may be made available.
Full o perat io nal checks sho uld be carried o ut in line wit h no rmal mo de
of operation t o ensure t he correct function and sett ing of each device.
5 OPERATION
5.1 GENERAL
A regular pro gramme of maint enance should be considered part of t he

nor mal operating procedure.
Except fo r maint enance purpo ses, it is no t no rmally necessary t o gain

access t o t he int erio r o f t he panel or any device aft er commissioning.
If Miniature circuit breakers t rip, t he cause must be ascertained and

remedial action t aken before t he device is put back int o service
5.2 DIRECTION OF OPERATING HANDLES
Manually operat ed devices carry labels clearly indicating t he normal

operating method.
6.1 GENERAL
Under normal service condit ions, a pro gramme of maint enance should be
carried o ut annually. For very frequent ly operat ed equipment ,
intermediat e maintenance intervals of 6 or even 3 months should be
considered. Aft er short circuit int erruption, t he cause must be
ascertained and remedial action t aken before put t ing back int o service.
As soo n as possible t hereaft er, t he ro utine maint enance programme
should be carried out.
6.1.1 SAFETY
Before carrying out any maint enance work, ensure t hat t he equipment is
isolated and safe and t hat all safety procedures and safeguards are being
applied (see Sectio n 1.1).
6.1.2 INSPECTION
All co nnect io ns should be checked fo r signs o f o verheat ing. Any

suspect jo int face sho uld be cleaned and pro perly t ight ened.
Check t hat t here adequat e clearance between phases and t o eart h and
t hat all mo uldings, shro uds and barriers are in go o d co ndit io n and
pro perly fit t ed. Any accumulatio n o f dust sho uld be remo ved,
preferably wit h t he aid o f a vacuum cleaner.
6.1.3 MEGGER TESTS
Iso lat e all light current devices by isolat ing cont ro l MCBs. Remo ve all
main neut ral links. Disconnect vo lt age reference wires fro m electro nic
component s, e.g. Pro t ect ion Relays etc. Wit h 1000-volt megger check
IR between phases, each phase t o neutral, each phase and neutral t o
earth, DC circuits to earth. Significantly reduced readings will probably
be due t o a build up o f dust o n, o r dampness o f, t he insulatio n.
However if, aft er cleaning and/o r drying t he insulatio n, readings are still
unacceptable advice sho uld be sought fro m t he manufact urer s.
When accept able readings have been obtained swit ch ÒN' MCBs and
replace all links and connectio ns et c. and carry o ut o perat io nal checks
t o confirm t hat t he correct connect ions have been made.
6.1.4 OPERATIONAL CHECKS
Carry out t he operational checks detailed in Sect ion 4.3
6.2 DEVICES
6.2.1 INSTRUMENTS, METERS AND RELAYS
Check t he set t ings and adjust t he necessary all pro t ection relays, t rips
and overload devices. Ensure t hat all pro t ective devices, auxiliary and
cont ro l equipment etc. are in sound working or der and t heir operation
results in correct operation of the equipment they contro l.
6.2.2 MINIATURE CIRCUIT BREAK ERS
These are facto ry sealed units and no maintenance is required ot her than
t o check t hat all cable and connect ion joint s are t ight and t hat all
insulat io n shro uds, screens and barriers are in place and secure.
6.2.3 CONTACTOR, RELAY AND GENERAL PANEL EQUIPMENTS
Check for any signs of damage or overheating. Check that all time delay
o r o verlo ad devices are correctly set . Check t he o perat io n o f any
mechanical or electrical int erlocks. Check t hat all connections are t ight
and t hat all insulat io n, shro uds, screens and barriers are in place and
secure. Check all component s for correct operation.
7 TRANSPORTATION TO SITE:
7.1 LOADING
7.1.1 Ensure t hat t he equipment s t o be t ransport ed are ready for lift ing/
t ransport and ensure t hat area around t he equipment is clear of
obstacles.
7.1.2 Use suit ably sized fo rklift o r crane fo r lo ading t he equipment
7.1.3 Ensure that the floo ring of trailer used for transport ing the
equipment is perfectly flat.
7.1.4 Load equipment on t he t railer carefully on woo den blocks t o avoid

slipping and wit h t he use of suit ably sized steel slings.
7.1.5 The equipment will be t ied wit h stro ng belt s t o keep it in posit ion
during transport ation.
7.1.6 The t railer shall be driven slowly t o sit e.
7.2 UNLOADING
7.2.1 The access t o t he sit e shall be checked during sit e survey and
t here shall be no obst acles for t he movement of t he
t railer/crane.
7.2.2 Release all belt s used t o ho ld equipment o n t railer.
7.2.3 Unlo ad equipment s wit h suit ably sized cranes/fo rklift s.
7.2.4 Equipment s are t hen shift ed t o it s final posit ion wit h t he

substation by means of 16mm diameter long ro ds. The
equipment is ro lled on t hose ro ds.
ANNEXURE – 1
List o f devices used in contr ol and relay panels
Sl.No. DESCRIPTION TYPE MAKE
RELAYS
1 BIASED DIFFERENTIAL PROTECTION RELAY P631 AREVA

NON DIRECTIONAL OVER CURRENT AND EARTH FAULT
2 P121 AREVA
PROTECTION RELAY
DIRECTIONAL OVER CURRENT AND EARTH FAULT
3 P127 AREVA
PROTECTION RELAY
4 RESTRICTED EARTH FAULT PROTECTION RELAY P120 AREVA
5 BREAKER FAILURE PROTECTION RELAY P821 AREVA
6 DIFFERENTIAL PROTECTION RELAY 7SD6101 SIEMENS
7 PILOT WIRE PROTECTION RELAY SOLKOR - R/RF REYROLLE

8 CABLE DIFFERENTIAL PROTECTION RELAY SOLKOR - N REYROLLE
MMLG01/MMLB0
9 TEST TERMINAL BLOCK AND TEST PLUG 1
AREVA
10 VOLTAGE REGULATOR RELAY RVM 5 REYROLLE
TRANSDUCERS
1 WATT TRANSDUCER T21 ENERDIS
2 VAR TRANSDUCER T21 ENERDIS

3 VOLTAGE TRANSDUCER T11 ENERDIS
4 CURRENT TRANSDUCER IAN 1210B ENERDIS
CT'S & PT'S

1 ISOLATING CURRENT TRANSFORMER - KAPPA
PUSH BUTTONS & INDICATING LAMPS

TELEMECANIQU
1 PUSH BUTTONS XB5-AA E
2 INDICATING LAMPS HXL FUJI
TELEMECANIQU
3 ILLUMINATED PUSH BUTTONS XB5-AW E
4 PUSH BUTTONS 3SB3201 SIEMENS
SWITCHES
KRAUS &
1 CONTROL SWITCH CA10 NAIMER
CRAIG &
2 VOLTMETER SELECTOR SWITCH R6VI/1 DERRICOTT
KRAUS &
3 DISCREPANCY SWITCH CA10 NAIMER
TELEMECANIQU
4 DOOR SWITCH XCK-P145 E
SEMAPHORE POSITION INDICATORS AND ANNUNCIATOR

RELAYS
1 SEMAPHORE POSITION INDICATOR SPR-30 FUJI
2 ANNUNCIATOR RELAY TKL121 FUJI
METERS
1 AMMETER 244-03A CROMPTON
2 VOLTMETER 244-03V CROMPTON
3 WATTMETER 244-218 CROMPTON

4 VARMETER 244-31L CROMPTON
5 POWER FACTOR METER 244-136 CROMPTON
6 AMMETER WITH MDI 244-16C CROMPTON

7 TAP POSITION INDICATOR PQ96K MR
TERMINAL BLOCKS
1 FITTED TYPE UK5N PHOENIX
4 FITTED TYPE UKK 5-DIO/O-U PHOENIX
5 TEST DISCONNECT TYPE URTK/S PHOENIX
6 ACCESSORIES FOR ABOVE PHOENIX
7 15kV INSULATED TERMINAL PPT35 WEIDMULLER

8 ACCESSORIES FOR ABOVE WEIDMULLER
MCB'S
1 AC MCB C60N MERLIN GERIN
2 DC MCB C32H MERLIN GERIN
3 AUXILIARY SWITCH CONTACT FOR AC MCB & DC MCB OF MERLIN GERIN
AUXILIARY RELAYS AND TIME DELAY RELAYS

CONTROL RELAY FOR MULTIPLICATION, INTERLOCK
1 3RH11 SIEMENS
CIRCUITS,ETC.,
LATCHING RELAY FOR MULTIPLICATION, INTERLOCK
2 3RH14 SIEMENS
CIRCUITS,ETC.,
3 AUXILIARY BLOCK FOR 3R1 CONTROL & LATCHING RELAYS 3RH19 SIEMENS
4 CONTROL RELAY FOR ARC PROTECTION SSP43 WIELAND
5 TIME DELAY RELAY 3RP1505 SIEMENS
OTHER ACCESSORIES
LOWE &
1 DOOR HANDLES 1617-522 FLETCHER
**********

Volume Ii - 250kva Trensformers, Ner, Nic & Ancillary Electrical Equipment PDF

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Volume Ii - 250kva Trensformers, Ner, Nic & Ancillary Electrical Equipment PDF

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STATE OF KUWAIT

MINISTRY OF ELECTRICITY AND WATER -

OPERATION & MAINTENANCE

Operational and Maintenance Manuals

Volume I – 145kV Gas Insulated Switchgear and Cranes

Section 1 – 145kV Gas Insulated Switchgear

☞Volume II – 250kVA Transformers, Neutral Earthing Resistors,

Section 1 – 250kVA 11/0.433kV Transformers

Section 2 – Neutral Earthing Resistors & Neutral Isolator Cabinets

Section 3 – Low Voltage 415V AC Distribution Boards

Section 4 – Power Cables

Section 5 - Control, Relay, Pilot Marshalling, Telemetry Terminal Transfer panels

Volume III – 30MVA Transformers

30MVA 132/11.5kV Transformers

Volume IV – 11kV Metal clad Switchgear

11kV Metal clad Switchgear

Volume V – Batteries and Chargers

Section 1 – Control system - Battery, Charger and DC distribution board

Section 2 – Trip system - Battery, Charger and DC distribution board

Section 3 – Emergency system – Battery and Charger

Volume VI – Protection and Control Relays

AREVA – Biased differential transformer protection - MICOM P631

Section 1 – SIEMENS – Busbar Protection – SIPROTEC 7SS60

Section 2 – SIEMENS – Line Differential Protection – SIPROTEC 7SD610

AREVA – Non Directional Overcurrent & Earth Fault Relay

Section 1 – AREVA – Directional Overcurrent & Earth Fault Relay

Section 2 – AREVA – Breaker Failure Protection MICOM P821

Section 1 – REYROLLE – Earth Fault Relay ARGUS-1

Section 2 – REYROLLE – Line Differential Protection SOLKOR-N

Section 3 – REYROLLE – Line Differential Protection SOLKOR-Rf

Section 4 – REYROLLE – RVM Voltage Regulation Relay SUPERTAPP

Section 5 – AREVA – Test Blocks MMLG 01

Section 6 – FUJI – Fault Indicators

Section 7 – FUJI – Semaphore Relays

Section 8 – TECSYSTEM – Temperature Monitoring Relay T-119

Section 9 – ENERDIS – Transducers TRIAD

Section 10 – CROMPTON – Meters

Volume VII - Intertrip Equipment

Intertrip Equipment – NSD570

Volume VIII - Fire Fighting

Section 1 – Water Fire Fighting System

Section 2 – Mobile Fire Extinguishers

Section 3– Fire Alarm System

Section 4– Fire Alarm and Detection Panels

Subject Three phase transformer, type TAT/R

Customer MITSUBISHI ELECTRIC CORPORATION

Ref. MINISTRY OF ENERGY – KUWAIT

I.LORA A.COSTA I.LORA 26/07/07 First Issue 00

Insulation distance from live part of transformer

CONNECTING TO THE MAINS.

Prior to energising the transformer there are a few points to be considered:

CU/CU plate M10 8.8 50Nm

CU/CU plate M12 8.8 60Nm

CU/CU plate M14 8.8 90Nm

CU/CU plate M16 8.8 150Nm

Links of tap changer M12 Brass 20Nm

Links of tap changer M10 Brass 15Nm

Links of tap changer M8 Brass 12Nm

Links of tap changer M6 Brass 10Nm

H.V connexion M20 Brass 80Nm

H.V connexion M16 Brass 60Nm

H.V connexion M12 Brass 40Nm

Insulation class Shock peak Minimum distance (mm)