Electrical 1 of 2

ELECTRICAL – BOOK 1 OF 2
ELECTRICAL
BOOK 1 OF 2
1
2

CRAFT APPRECIATION FOR ENGINEERS (CAFE)

ELECTRICAL
Book 1 of 2
TABLE OF CONTENTS
MODULE / UNIT / LESSON PAGE

1 SEC NETWORK, STANDARDS AND GENERATORS 9
1.1 SEC Network 13
Task 1.1-1: Power System Simulator – Generation, Transmission and 37
Distribution
1.2 SEC Standards and Manuals 39
1.3 generators and Excitation System 69
Task 1.3-1: Operation of Polyphase Alternators using Power System 99
Simulator
2 MOTORS AND POWER TRANSFORMERS 101
2.1 Types of Motors, Protection andControl 105
Task 2.1-1: Demonstrate Motor Control Circuits 139
2.2 Transformer Components, Operating Voltages and Cooling System 141
2.3 Transformer Tests 153
3 TRANSMISSION SUBSTATIONS 165
3.1 Transmission Substation Components, Operating Voltages and Diagrams 169
3.2 Busbars and Circuit Breakers ˺́ 5
4 DISTRIBUTION SUBSTATIONS 209
4.1 Distribution Substation Types, Components and Voltage Levels 213
Task 4.1-1: Demonstrate Distribution Network in Outside Yard 239
Task 4.1-2: Identify secondary and customers distribution equipment 240
4.2 Meter Types and Classifications 241
5 ELECTRICAL DIAGRAMS, SWITCHING, LINEMAN AND CABLEMAN 261
5.1 Electrical Diagrams 265
Task 5.1-1: Isolating Power Transformer (T-703) 230 /69 kV 279
5.2 Switching Activities 283
Task 5.2-1: Energizing Power Transformer (T-703) 230 /69 kV 297
5.3 Lineman and Cableman Activities 301
5.4 Cable Splicing Activities 321
3
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ELECTRICAL
Book 1 of 2
PACING SCHEDULE
UNIT LESSON TITLE DURATION
(Hrs)
1 GENERAL INTRODUCTION 6
1.1 SEC Network 2
Task 1.1.1 Power System Simulator–Generation
1.2 SEC Standards and Manuals 1
1.3 generators and Excitation System 3
Task 1.3-1: Operation of Polyphase Alternators using Power System
Simulator
2 MOTORS AND POWER TRANSFORMERS 6
2.1 Type of Motors, Protection and Control 3
Task 2.1.1 Demonstrate Motor Control Circuits
2.2 Transformer Components, Operating Voltages and Cooling System 2
2.3 Transformer Tests 1
3 TRANSMISSION SUBSTATIONS 5
3.1 Transmission Substation Componts, Operating Voltages and Diagrams 3
Busbars and Circuit Breakers
3.2 2
4 DISTRIBUTION SUBSTATIONS 6
4.1 Distribution Substation Types, Components and Voltage Levels 3
Task 4-1-1 Demonstrate Distribution Network in Outside Yard 1
Task 4.1-2: Identify secondary and customers distribution equip.
4.2 Meter Types and Classifications 2
5 ELECTRICAL DIAGRAMS AND SWITCHING ACTIVITIES 6
5.1 Electrical Diagrams 1
Task 5.1-1: Isolating Power Transformer (T-703) 230 /69 kV
5.2 Switching Activities 2
Task 5.2-1: Energizing Power Transformer (T-703) 230 /69 kV
5.3 Lineman and Cableman Activities 1.5
5.4 Cable Splicing Activities 1.5
Total 29
5

6


ELECTRICAL
Book 1 of 2
COURSE OVERVIEW
DESCRIPTION
The course is divided into two parts, Electrical and Mechanical, two books for each,
with six units in Electrical and and ten units in Mechanical. The participants will
acquire necessary know ledge and skills needed to perform various performance tasks
in different electrical crafts, in accordance with the SEC standard field practices and
procedures.
OBJECTIVES
Upon completion of this course, the participants should be able to:

∑ Familiarize with SEC Network
∑ Familiarize and access SEC Standards and Manuals to record proper records of
backup equipment, electrical drawings and documents and updating all as required.
∑ Perform tasks related to generators and Excitation Systems, Motors. Power
Transformers, Transmission and Distribution Substations (Equipment, Switching).
∑ Give directions to Linemen and Cableman and perform related tasks.
∑ Enforce safety procedures and precautions for Power System Protection and
Control including Power Dispatcher.
∑ Familiarize with Telecommunications Equipment and its Operation and
Maintenance.
∑ Familiarize with Supervisory Control and Data Acquisition (SCADA) Equipment
and its Operation and Maintenance.
7

8

UNIT-1
SEC NETWORK, STANDARDS

AND GENERATORS
9

10

UNIT-1
SEC NETWORK, STANDARDS AND GENERATORS
UNIT OVERVIEW
DESCRIPTION
Lesson 1.1 familiarizes the participants with different electrical crafts in SEC
Network and their Duties and Responsibilities, as Substation Maintenance Technician,
Relay Technician, Cableman, Lineman, Network Operator, Instrument Technician,
Power Plant Operator, Power Plant Electrician, Distribution Electrician, Water
Treatment Plant Operator, Telecom Technician, and SCADA Technician.
∑ Lesson 1.2 familiarizes the participants with SEC Standards for Transmission
Material Standards' Specifications (TMSS), Transmission Engineering
Specifications (TES), Transmission Construction Specifications (TCS).
Transmission Development Specifications (TDS), Saudi Electricity Company
Engineering Drawings' Standards (SEEDS), SEC Distribution Material
Specifications (SDMS), Design Standards for Construction of Distribution
Systems (SDCS), Customer Service Manual (CSM), Distribution Safety Manual
(DSM), Distribution Operation Manual (DOM), Distribution Maintenance M anual
(DMM), Distribution Planning Standards (DPS), Craft Certification Manuals
(CCMs).
This lesson demonstrates how the Standards/Manuals are accessed to keep up -to-date
records of stock items, documents and drawings.
In Lesson 1.3, generators and Excitation System include Stator, Rotor, Bearings,
Lubrication System, Thermocouples, Seal Oil System, Main Leads, Current
Transformers, Neutral Grounding Transformer and Resistor-Temperature Detectors,
Generator Frame, Generator Cooling, Hydrogen Blower and Cooler, Hydrogen Gas
System, Gland Seals System, Excitation System, Brush and Slip Ring Excitation,
Brushless Excitation, Parallel Operation of Generators.
The lesson concludes with Preventive Maintenance.
11

OBJECTIVES
Upon completion of this unit, the particip ants should be able to familiarize with:
∑ SEC Network
∑ Duties and Responsibilities of electrical Crafts in SEC Network as:
Substation Maintenance Technician, Relay Technician, Cableman, Lineman,
Network Operator, Instrument Technician, Power Plant Operator, Power Plant
Electrician, Distribution Electrician, Water Treatment Plant Operator, Telecom
Technician, SCADA Technician
Task 1.1-1 Power System Simulator–Generation, Transmission and Distribution
∑ Standards/Manuals and their Accessibility
Transmission Material Standards' Specifications (TMSS), Transmission
Engineering Specifications (TES), Transmission Construction Specifications
(TCS). Transmission Development Specifications (TDS), Saudi Electricity
Company Engineering Drawings ' Standards (SEEDS), SEC Distribution Material
(DSM), Distribution Operation Manual (DOM), Distribution Maintenance Manual
(CCMs)
∑ Power Plant generators and their operation.
∑ Generator components and their functional characteristics including:
Stator, Rotor, Bearings, Lubrication System, Thermocouples, Seal Oil System,
Main Leads, Current Transformers, Neutral Grounding Transformer and Resistor-
Temperature Detectors (RTD), Generator Frame, Generator Cooling, Hydrogen
Blower and Cooler, Hydrogen Gas System, Gland Seals System.
∑ Excitation Systems including Brush and Slip Ri ng Excitation, Brushless Excitation
with Parallel Operation of Generators.
∑ Preventive Maintenance of generators in Power Plants.
Task 1.1-3: Operation of Polyphase generators using Power System Simulator
12

LESSON 1.1
SEC NETWORK
13

14

LESSON 1.1
SEC NETWORK
LESSON OVERVIEW
DESCRIPTION
This lesson familiarizes the participants with different electrical crafts in SEC
Network and their Duties and Responsibilities as Substation Maintenance Technician,
Relay Technician, Cableman, Lineman, Network Operator, Instrument Technician,
Power Plant Operator, Power Plant Electrician, Distribution Electrician, Water
Treatment Plant Operator, Telecom Technician, and SCADA Technician.
OBJECTIVES
Upon completion of this lesson, the participants should be able to i dentify:

Generating Sets and Network Generation Plants:
∑ Hydro Generation Plants
∑ Steam Generation Plants
∑ Gas Turbine Generation Plants
∑ Internal Combustion or Diesel Engine Plants
Distribution Substations:
∑ Typical Distribution Substation
∑ Load and Network Action
Power System:
∑ Switchyard Components and Interconnected Transmission
∑ Power Network Stages and Voltage Level
∑ Indoor Switchyard and Transmission Tower s
∑ Buses Arrangement in Open Switchyard
∑ 115/13.8 kV Substation Switchyard
∑ Switching Stations, Sub -transmission and Bulk Supply Point
∑ Primary Distribution and Typical Primary Feeder
∑ Secondary Distribution and Secondary Feeders
∑ Industrial Customers
∑ O&M Crafts Distributed across Power Systems
Task 1.1.1 Power System Simulator–Generation, Transmission and Distribution
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16

SEC NETWORK OVERVIEW

SEC power network, like any major modern utility company, includes generation
plants (steam and gas), transmission lines (OH lines and UG cables) and
substations and distribution systems to serve the connected loads ( Fig. 1.1-1).
Fig. 1.1 -1 SEC Power Network
Substations in the network serve different purposes, mainly, voltage level

transformation in the network stages. This is achieved by power transformers,
power flow control by circuit breakers and bus bar sections. Also, substations
have metering, monitoring relays and system protection instruments ( Fig . 1.1-2).
Fig. 1.1-2 Substation
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GENERATION
The major Electrical Power System components are used either in generation or
transfer of elec tricity.
GENERATING SETS
Each generator in a power plant is driven by its own prime mover (driver). A
turbine or a motor is a prime mover . Each generator is attached to its own prime
mover to make up a single unit or a set. The term generating set includes both a
prime mover and a generator.
You know that electrical power output is proportional to mechanical power input.
A generator design capability (maximum output or maximum load) is expressed
in electrical units, such as 10 Mega-Watts (10 MW).
Also one HP of mechanical energy equals 746 watts of electrical energy. So a

generator rated at 10 MW maximum output requires a diesel engine or gas turbine
rated at (10000000/746 ) HP to drive it or 13400 HP (plus about 10% allowance
for energy used in overcoming friction, air resistance and producing unavoidable
heat). That is about 14500 - 15000 HP (Fig . 1.1-3).
Fig. 1.1-3 Prime Mover and Generator
NETWORK
A network is an advanced type of electrical power system. An electrical network
consists of several power plants. They are connected together by transmission lines (or
cables) and switchgear ( Fig. 1.1-4). Each power plant in the network acts as part of a
"team" instead of working alone. The term "electrical power system" and "electrical
18

power network" are used to describe this team. "SEC electrical power generation
system" and "SEC network" both mean the same as the whole system involving all the
power.
Electric power is generated for community use by

different types of generation plants as fo llows:
Fig. 1.1-4 Electrical Network
1. HYDRO GENERATION PLANTS

The basis of hydroelectric power
generation (Fig. 1.1-5) is that water
at height has certain potential energy.
The height is referred to as the head.
The maximum power obtained from
a hydro plant may be computed by
multiplying the head, water density, Fig. 1.1-5 Hydro Generation Plants
and volumetric flow rate.
2. STEAM GENERATION PLANTS

The steam is created by a boiler, where pure water passes throug h a series of tubes to
capture heat from the firebox and then boils under high pressure to become
superheated steam. The heat in the firebox is normally provided by burning fossil fuel,
coal, fuel oil or natural gas (Fig. 1.1-6).
However, the heat can also be provided by solar energy or nuclear fuel. The
superheated steam leaving the boiler then enters the steam turbine throttle, where it
powers the turbine and connected generator to make electricity. After the steam
expands through the turbine, it exits th e back end of the turbine, where it is cooled and
condensed back to water in the surface condenser. This condensate is then returned to
the boiler through high-pressure feed pumps for reuse. Heat from the condensing
19

steam is normally rejected from the condenser to a body of water, such as a river or
cooling tower. Steam turbine power plants operate on a Rankin cycle.
Fig. 1.1-6 Essential Components of Steam Electric Power Generation Plants
Steam Turbine Rankin Cycle
Fig. 1.1-7 Rankin Cycle for Steam Turbine

The cycle (Fig. 1.1-7) consists of four processes:
1 to 2 Isentropic expansion (Steam turbine),
2 to 3 Isobaric heat rejection (Condenser)
3 to 4 Isentropic compression (Pump)
4 to 1 Isobaric heat supply (Boiler)
20

3. GAS TURBINE GENERATING PLANTS

The gas turbine generating plants (Fig. 1.1-8) convert heat energy into electric energy.
In the gas turbine, air is compressed by the compressor into the combustion chambers
where it mixes and burns with the fuel. The combustion gases then flow through
turbine section producing driving power as it expands in the stages of the turbine.
Then the turbine drives the generator. The fuel can be either gas or liquid fuel. In case
of liquid gas, a process of purification and atomization before injecting it to the
combustion chamber is followed. Fig. 1.1-8 shows schematically the components of a
gas turbine plant. Gas turbine power plants operate on a Brayton cycle.
Fig. 1.1-8 Components of Gas Turbine Plant
Gas turbine Brayton Cycle

In Fig. 1.1-9, air is compressed from point 1 to point 2 (Compressor). This increases
the pressure as the volume of space occupied by the air is reduced. The air is then
heated at constant pressure from 2 to 3 (Combustor). This heat is added by injecting
fuel into the combustor and igniting it on a continuous basis. The hot compressed air
at point 3 is then allowed to expand from point 3 to 4 (Turbine) reducing the pressure
and temperature and increasing its volume.
21

Fig. 1.1-9 Gas Turbine Brayton Cycle
Combined Cycle Power Plant

As opposed to a Simple Cycle Power Plant that is not very efficient as the heat from
the turbine is "wasted" to the atmosphere, a Combined Cycle Power Plant (CCPP)
(Fig. 1.1-10) recovers this heat. CCPPs, also referred to as "Combined Cycle
Cogeneration, is a natural gas (or diesel) turbine coupled with an electrical generator
together, referred to as a "GEN-SET". The exhaust heat from the gas turbine is
directed to a Waste Heat Recovery Boiler (WHRB) or Heat-Recovery Steam
Generator (HRSG). The steam from WHRB or HRSG is directed to a steam turbine
generator where the steam is used to power the steam turbine Gen-Set. By capturing
the waste heat of the gas turbine in a Combined Cycle Power Plant and putting it to
work, the overall thermal efficiency of the plant is increased. In a typical cogeneration
plant, electric power is generated but some of the steam from the WHRB or HRSG is
used for process heat. The combined-cycle power plant combines the Rankin (steam
turbine) and Brayton (gas turbine) thermodynamic cycles by using heat recovery
boilers to capture the energy in the gas turbine exhaust gases for steam production to
supply a steam turbine as shown in the Fig. 1.1-10 for "Combined-Cycle
Cogeneration". Process steam can be also provided for industrial purposes.
22

Fig. 1.1-10 Combined Cycle Power Plant
4. INTERNAL COMBUSTION ENGINE PLANTS / DIESEL ENGINE PLANTS

The diesel engines are piston cylinder engines
that burn diesel fuel and drive generators
coupled to the engine by the engine crank
shaft. These types of plants are used to serve
remote villages that cannot be served directly
from the grid. Also, these plants are usually
mobile type. Fig. 1.1-11 shows a typical I.C.E.
Fig. 1.1 -11 Diesel Engine coupled
generating unit.
directl y to Generator
Load
The amount of electrical power needed or demanded by the user at any
particular moment of time is usually referred to as Load. The load can vary a
great deal from hour to hour, from day to day and from one part of the year to
another part. For example in the evening , more power is used for lighting and
cooking. On holidays, less power is used by industry and in very hot weather
more power is used for air conditioning. Before installing generators, it is
necessary to know how much electricity is likely to be needed by the user, as in
the following example.
23

In Fig . 1.1 -12 , user is a small town or village. If the maximum predicted load
(or estimated peak demand ) for electrical power by the village is taken as 10
MW, the generating capacity of the power plant must not be less than 10 MW. A
power system with all generating stations and all load areas connected in
parallel may be represented by a theoretical diagram as shown .
Fig . 1.1-12 Power System
Here, the network is shown as "Reservoir " of electrical power with generating
stations "a", "b", "c" and "d" pumping power into the reservoir and load areas
A, B, C, D drain ing power out.
Network Acti on
In Fig. 1.1-13 , the large load area B (20 MW) is fed from station b with four
generators ; while load area C (5MW) is supplied by the single unit in station
"c", "a" producing 15 MW ; with 12 MW going to area A , 1MW to isolated area
E , and 2MW to being exp orted to area B .Note that area B requires 20 MW but
station "b" can produce a maximum of only 18 MW, as two of generating sets
are "off -line").
Power plant "c" (one generator) is also off-line, so plant "d" (four operational
generating sets is simultaneou sly supplying its own area D (23 MW)) plus area C
and area F (5MW + 2MW). At this particular time , there is zero flow in the
transmission line between plants "a" &"c".
24

Fig. 1.1-13 P o wer Fl o w in a th eo r et ical Net wo r k

Plant "g" is a small, single -generator "emergency" station, which can be put on
line to help out during abnormal conditions. The power plants in a network can
supply loads to anywhere in the network. But it is easier and cheaper to supply
loads to the local area. So plants are located near the most of its users or its
principal load area. The power plant normally supplies the load to all users in its
area, but there is still a need for electrical power to be transmit ted over long
distances as economical as possible.
Long distance transmission lines serve two purposes:

∑ Supply power to isolated secondary load areas
∑ Transfer electrical power between power plants.
Power System
The purpose of SEC electrical network is to generate and transfer electricity from the
generation plant to the user. SEC power plants are all connected together by
transmission lines and switchyards. The electrical grids in SEC involve many
generation plants. The grid system must be economical and reliable to eliminate or
reduce the need for additional stand -by generating units. Also, the grid system is more
reliable in satisfying the peak load, which takes place for several hours at particular
times of the day. The grid system allows the power plants to work as a team.
Switching and transmission substations connect the generators of the power plant to
the transmission lines.
25

Fig. 1.1-14 shows the components and

the layout of these substations, which are
found in the backyard of the power plant.
These power plant substations are called
Switchyards.
Fig. 1.1-14 Components and Switches of

Switch Yard
Fig. 1.1-15 shows how a transmission system is interconnected. G1, G2 and G3 are
power plants that are hundred kilometers apart and 1, 2, 3, 4, 5, 6 and 7 are
interconnected bus bars and Transmission Lines (TL). Each has a circuit breaker (CB)
at both ends. SLs are transmission lines traveling to a load center, called Bulk Supply
Points (BSPs).
Fig. 1.1 -15 Interconnected Transmission Power System
26

In BSPs, transmission voltage i s stepped down to suit sub -transmission stage of the
network. Fig. 1.1 -16 shows different stages of SEC-East power system from
generation to customer supply. Voltage levels for transmission within SEC
network are 380 kV, 230 kV, 115 kV and 69 kV. Electric power is generated at a
voltage level of 13.8 kV. A step-up power transformer is used to raise the
generation voltage up to the transmission voltage. To protect the system against
any failure, nearly all circuits are connected to the system through Circuit
Breakers , which are tripped open automatically on fault occurrence. Transmission
of electric power at high voltage reduces the conductor size required for traveling
long distances, the electric power losses and minimizes the voltage drop between
the sendi ng and receiving ends.
Fig. 1.1-16 Power Network Stages and Voltage Level
27

Switching Stations
Switching stations serve the purpose of sectionalizing the system. There are two
principal reasons for sectionalizing. The first is to disconn ect the system from
faulty or short circuits. Few short circuits are self -clearing. When a circuit or piece
of apparatus becomes defective , it is usually necessary to de -energize it to clear the
trouble. Most of the power circuits are connected to the system through Circuit
Breakers to avoid shutting down the whole system every time there is a short
circuit anywhere so that CBs are tripped open automatically. The second reason for
sectionalizing is to facilitate maintenance or new construction.
When it is necessary to de-energize a circuit, however, it is desirable to keep in

operation as much of the system as possible . Circuit Breakers are used, therefore,
to cut off only the selected circuit. Thus, switching stations are substations whose
function is switching circuits in and out of service. Without the transformer, this
would look like a pure switching station.
Sub-Transmission
Sub-transmission usually designates that part of the system between the
transmission and the distribution systems. If a generating plant is located in or
close to the load, there may be no transmission lines from that plant. It will then
feed directly into the sub-transmission or distribution system. The voltage of the
sub-transmission system is intermediate between the transmission and the
distribution voltages.
Bulk Supply Point

This is sometimes called sub-transmission and distribution substation. The
equipment found in such a substation would include power and instrument
transformers, lightning arresters, circuit breakers, discon nect switches, capacitor
banks, bus work and a control house in which station control equipment, protective
relays, etc. are located. Some primary substations might include more equipment
depending upon the functions they are intended to perform. Some stations are
manually operated and others are completely automated.
28

Distribution Substations
The distribution system is fed through grid substations. They are of a large capacity
and supply power to a large area through many primary feeders. Some are close to the
load but small and control only a few feeders, for example, a single circuit unit
substation. Each primary feeder is supplying several distribution substations. A
distribution substation is shown in Fig. 1.1-17. The distribution substation includes
two types of primary distribution and secondary distribution.
Fig. 1.1-17 Distribution Substation in SEC Network
Primary Distribution
Primary distribution takes the power from the grid or 115 kV/13.8 kV distribution
substations to the final step -down operat ions for residential areas.
Secondary Distribution
This is the part of the system through which the power finally reaches a large
number of the customers, except the industries and other large-usage consumers.
29

Secondary distribution feeders are mainly the buried cable (UG) between the LV
panel and the minipillar.
Industrial Customers
Small industrial customers are served directly by the primary feeders or possibly
from the sub -transmission system. Large industrial customers are fed directly from
the sub-transmission system and very large industrial customers may be served
from the transmission system (Fig . 1.1-18).
Fig. 1.1-18 Different Stages of Power System
DUTIES AND RESPONSIBILITIES OF ELECTRICAL

CRAFTS IN SEC NETWORK
Electrical crafts in SEC network perform a variety of semiskilled or manual duties
involved in the construction, installation, maintenance and repair of electrical systems,
facilities and equipment , as follows:
30

POWER PLANT ELECTRICIAN (Fig. 1.1-19)

∑ Repair and maintenance for power plant equipment including motors, low and
medium voltage operation and control circuit breakers.
∑ Repair and maintenance for
the electrical, fire fighting and auxiliary systems.
∑ Generator and illumination inspection as well a s pulling power s tation cables.
Fig. 1.1-19 Power Plant Electrician

NETWORK OPERATOR (Fig. 1.1-20)
∑ Test the equipment before
operation in transmission and
distribution network.
∑ Disconnect and isolate the
electrical equipment for safety
in maintenance.
∑ Disconnect the failure parts for
safety in maintenance.
∑ Inspect the equipment and
Fig. 1.1-20 Network Operator
record the loads.
31

DISTRIBUTION ELECTRICIAN (Fig. 1.1-21)

∑ Erect and maintain electrical energy
measurement meters.
∑ Maintain, repair and inspect
transformers, Circuit Breakers, main/
auxiliaries electrical distribution
boards.
∑ Connect low voltage cables.
Fig. 1.1-21 Distribution Electrician
RELAY TECHNICIAN (Fig. 1.1-22)

∑ Erect, maintain and test protec tive relays.
∑ Inspect, connect and test voltage and
current transformers.
∑ Troubleshoot and repair medium and high
voltage equipment by following electrical
wiring diagrams.
∑ Test and calibrate instruments and Fig. 1.1-22 Relay Technician
recording devices and other electrical
equipment.
INSTRUMENT TECHNICIAN (Fig. 1.1-23)

∑ Inspect, repair and calibrate control and
protection devices which used in the
generation power plant.
∑ Calibrate and repair the instrument
devices for pressure, temperature, flow
and level.
∑ Adjust and calibrate the control valves
and measurement record ers.
Fig. 1.1-23 Instrument Technician
32

SCADA TECHNICIAN (Fig. 1.1-24)

∑ Maintain and reapir electronic
circuit components including
conductors, semi-conductors,
digital logic circuits and electronic
cards.
∑ Maintain and reapir different
electronic welding circuits.
∑ Maintain and reapir SCADA
systems and related equipment. Fig. 1.1-24 SCADA Technician
TELECOM TECHNICIAN (Fig. 1.1-25)

∑ Maintain and reapir electronic circuit
components including conductors,
semi-conductors, digital logic circuits
and electronic cards.
∑ Maintain and reapir different
electronic welding circuits.
∑ Maintain and reapir telecom systems
Fig. 1.1-25 Telecom Technician
and related equipment.
WATER TREATMENT PLANT OPERATOR (Fig. 1.1-26 )
∑ Maintain and reapir water treatment
equipment.
∑ Maintain and reapir pumps, filters
and electrical equipment .
∑ Maintain and reapir
chemical
quantity including PH and
conductivity for water.
Fig. 1.1-26 Water Treatment Plant

Operator
33

POWER PLANT OPERATOR (Fig. 1.1-27)

∑ Prepare, operate and supervise all the
rotating and non-rotating equipment inside
the power plant fro local and remote site.
∑ Record and inspect the different systems in
the power plant.
∑ Inform the maintenance departments for any
Fig. 1.1-27 Power Plant Operator
abnormal conditions to troubleshoot and
repair.
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TASK 1.1-1
POWER SYSTEM SIMULATOR
GENERATION, TRANSMISSION AND DISTRIBUTION
OBJECTIVES
To become familiar with several operational modes of SEC Power System
Simulator:
∑ Loading a Generating Unit
∑ Isolati ng Generating Unit
∑ Loading Transmission Line
∑ Isolating Transmission Line
∑ Energizing Industrial Load
MATERIALS, TOOLS AND EQUIPMENT

1. Room 409 - Power system simulator
2. Hand outs on SEC Power System Simulator
SAFETY PRECAUTIONS
∑ Wear required safety equipment
∑ Keep a safe distance from energized equipment
∑ Follow your trainer's directions .
PROCEDURE
The participant must write down their own task steps according to instructor's
demonstration for their own performance.
37

38

LESSON 1.2
SEC STANDARDS AND MANUALS
39

40

LESSON 1.2
SEC STANDARDS AND MANUALS
LESSON OVERVIEW
DESCRIPTION
This lesson familiarizes the participants with SEC Standards for Transmission
Material Standards' Specifications (TMSS), Transmission Engineering Specifications
(TES), Transmission Construction Specifications (TCS). Transmission Development
Specifications (TDS), Saudi Electricity Company Engineering Drawings' Standards
(SEEDS), SEC Distribution Material Specifications (SDMS), Design Standards for
Construction of Distribution Systems (SDCS), Customer Service Manual (CSM),
Distribution Safety Manual (DSM), Distribution Operation Manual (DOM),
Distribution Maintenance Manual (DMM), Distribution Planning Standards (DPS),
Craft Certification Manuals (CCMs).
This lesson demonstrates ho w the Standards/Manuals are accessed to keep up -to-date

records of equipment, documents and drawings.
OBJECTIVES
Upon completion of this lesson, the participants should be able to be familiar with:
∑ SEC Standards/Manuals and their Accessibility:
Transmission Material Standards' Specifications (TMSS), Transmission
Engineering Specifications (TES), Transmission Construction Specifications
(TCS). Transmission Development Specifications (TDS), Saudi Electricity
Company Engineering Drawings' Standards (SEEDS), SEC Distribution Material
(DSM), Distribution Operation Manual (DOM), Distribution Maintenance Manual
(CCMs).
41

42

INTRODUCTION
It is very important for an engineer to know all the details of SEC standards and
perform his duties appropriately and reasonalbly as required. The engineer should
know the purpose of the distribution and transmission standards and be familiar with
the Accessibility to Standards/Manuals.
A - DISTRIBUTION STANARDS
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http://sec2/dist_cust/dist/DistStandard/index.asp
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1- Distribution Materials' Specifications (SDMS)

http://sec2/dist_cust/dist/DistStandard/SDMS/index.htm
This Specification describes the general requirements applicable to all the SEC
Distribution Materials' Specifications (SDMSs).
6' 0 6&2 ' ( ,7( 0
' ( 6&5 , 3 7 , 2 1 REV. DATE
General Requirements For All Equipment /
016' 0 601 1 12/2003
Material
43

13.8 & 33 kV Overhead Line Conductors (ACSR /

16' 0 610 0 01/2002
AW Type)
26' 0 610 %DUH
&RSSHU
&RQGXFW
RUV 0 03/2007
116' 0 6 1 Low Voltage Power And Control Cables 2 03/2007
26' 0 611 LV Overhead Line Conductor Type Quadruplex 0 01/2002
XLPE Insulated Power Cables For Rated Voltages
36' 0 611 1 11/2004
From 15 kV Up TO 36 kV
7 HUP LQDW
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8 SW
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126' 0 6 1 0 04/2003
˼˿kV
Lugs And Connectors For MV/LV Distribution
26' 0 612 1 03/2007
System
156' 0 6 1 OYHUKHDG
/ LQH
3RUFHODLQ
,QVXODW
RUV 0 07/1423
16' 0 620 Octagonal Steel Poles For Distribution Lines 1 06/1423
26' 0 620 2 YHU
+ HDG
/ LQH
$ FFHVVRULHV 1 03/2006
016' 0 630 / RDG
%UHDN
6ZLW
FKes 0 01/1423
02
6' 0 630 Disconnect And Bypass-Disconnect Switches 0 09/2005
016' 0 6
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3DQHOs 2 12/2006
31-SDMS-02 /
9' LVW
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3LOODUs 1 04/2004
Low Voltage Cabinet For Pole Mounted
31-SDMS-03 1 02/2007
Transformers
01/2007
Low Voltage Distribution Panels Without
31-SDMS-04 0
Outgoing Circuit Breakers
32-SDMS-01 SF6 Ring Main Units, 15 kV 1 04/2004

32-SDMS-02 M V Metered Ring Main Units up to 36 kV 0 09/2004
33-SDMS-01 M V Auto Reclosers up to 36 kV 0 09/2004
33-SDMS-02 M V Automatic Line Sectionlizers up to 36 kV 0 09/2004
34-SDMS-01 M V Dropout Fuse Cutouts 0 12/1423
34-SDMS-02 M V & L V fuse links 0 10/2003
44

356' 0 6 1 0 HW
DO
2 [ LGH
6XUJ H
$ UUHVW
HUV 0 12/1422
Low Voltage Molded Case Circuit Breakers For
376' 0 6 1 1 02/1424
Service Connections
Molded Case Circuit Breakers For Low Voltage
376' 0 6 2 0 01/2006
Distribution Panels 400 Amps
Molded Case Circuit Breakers For Low Voltage
376' 0 6 3 0 01/2006
PMT Cabinet 200 Amps
376' 0 6 4 Interface Low Voltage Main Circuit Breakers 0 02/2006
406' 0 6 1 Bottom Connected Kilo-Watt-Hour Meters 1 12/1423
406' 0 6 2 Electronic Kilo-Watt-Hour Meters 5 02/2007
426' 0 6 1 Fiber Glass Reinforced Polyester Meter Boxes 3 02/2007
436' 0 6 1 MV Shunt Power Capacitor Bank up to 36 kV 0 03/2005
436' 0 6 2 MV Step Voltage Regulators up to 36 kV 0 03/2005
506' 0 6 1 Current Transformers up to 36 kV 0 05/2004
516' 0 6 1 Distribution Transformers up to 36 kV 2 04/2004
566' 0 6 1 8 QLW
6XEVW
DWLRQV
N9
˺˼̄́ kV 1 04/2004
566' 0 6 2 3DFNDJ H
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2- CONSTRUCTION STANDARD FOR OVERHEAD LINES (SDCS-01)
The (SDCS-01) standard specifies the design, materials and installation practices to be
applied in the construction of MV and LV single and double circuit lines of overhead
distribution system with the use of octagonal steel poles as line supports. It is intended
to assist the engineers and field personnel to achieve standardization in construction
and to ensure a satisfactory and economical level of service without operating
restrictions so that the operational errors should be minimal for safety and reliability.
45

3- CONSTRUCTION STANDARD FOR UNDERGROUND

DISTRIBUTION NETWORKS (SDCS-02)
http://sec2/dist_cust/dist/DistStandard/SDCS2/index.htm
NUMBER ,7 ( 0
' ( 6&5 , 3 7 , 2 1 REV DATE
PART 1 Cable Trenches And Concrete Foundations 0 05/2005
Installation Of KWH Meters Inside Meter Rooms And

PART 2 0 05/2005
Insets
Installation Of Recessed Type KWH Meter Boxes Into
PART 3 0 09/2005
Consumer Walls
PART 4 Installation Of Distribution Pillars 0 02/2006
The (SDCS-02 – PART-1) construction standard s pecifies the design and installation
practices to be applied in the construction of MV and LV cable of underground
distribution system.
The (SDCS-02 – PART-2) construction standard specifies the design of meter room
and method of installation of KWH meters inside the meter rooms and building insets.
The (SDCS-02 – PART-3) construction standard specifies the design of wooden

frames for polyester meter cabinets to be installed recessed into the consumer wall.
The (SDCS-02 – PART-4) construction standard specifies the minimum requirements

for the distribution pillars to be installed on the foot path/leveled or unleveled roads.
4- DISTRIBUTION NETWORK GROUNDING CONSTRUCTION

STANDARD (SDCS-03)
http://sec2/dist_cust/DistStandard/SDC3/index.htm
NUMBER 1 ,7( 0
' ( 6&5 , 3 7 , 2 REV DATE
PART 1 Underground Network Grounding 0 05/2005
PART 2 Overhead Network Grounding 0 05/2005
46

The (SDCS-03 – PART-1) Grounding Standard describes the technical requirements

for grounding the SEC Distribution Network installations. This extends from the MV
(33 kV, 13.8 kV) feeder outlets of HV / MV Substations down to SEC Customer
interface including KWH-Meters and meter boxes.
The (SDCS-03 – PART-2) Grounding Standard describes the technical requirements

for grounding the SEC overhead Distribution Network installations. This extends from
the MV (33 kV, 13.8 kV) feeder outlets of HV/MV Substations down to SEC
Customer interface including KWH -Meters and meter boxes.
5- DISTRIBUTION OPERATIONS' MANUAL (DOM)

http://sec2/dist_cust/dist/DistStandard/DOM/index.htm
' 20
&2 ' ( ,7( 0
' ( 6&5 , 3 7 , 2 1 REV. DATE
DOM- 01- 01 Preparation of Distribution Operation Manual 0 04/2004
DOM- 01- 02 Lock And Locking Arrangement 0 04/2004
DOM- 01- 03 Operation between Control Center 0 12/2004
DOM- 01-04 Hold Tags 0 12/2004
DOM- 01- 05 Inspection Of VIP Customer Generators 0 12/2004
DOM- 01- 06 Operation Accident Error Investigation 0 05/2005
DOM- 01- 07 Work Permits 0 Not Yet
DOM- 01- 08 Load Readings 0 03/2006
DOM- 02- 01 Operation Of Switchgears 0 05/2005
DOM- 02- 02 Operation Of Package Substations 0 05/2005
The (DOM- 01- 01) Standard describes the guidelines for the preparation of
Distribution Operations' Manuals (DOM). The primary purpose of DOM is to provide
precise and adequate information to the engineer engaged in the operation of
distribution equipment and network. DOM will ensure that Operation of distribution
equipment and lines is carried out in accordance with international standards and
practices in consideration with cost effectiveness, safety and reliability.
47

The (DOM- 01- 04) Standard describes the guidelines for distribution power lines and
associated equipment below 69 kV and pro vide tagging and locking procedure s to be
implemented before issuing Electrical Work Permits. The purpose of this is to
safeguard persons and property from hazards arising in construction, Operation or
Maintenance Activities.
6- DISTRIBUTION MAINTENANCE MANU AL (DMM)

http://sec2/dist_cust/dist/DistStandard/DMM/index.htm
&2 ' ( ,7( 0 ' ( 6&5 , 3 7 , 2 1 REV DATE

* HQHUDOInstruction for Substation Inspection
DMM-01-01 0 12/2005
& Maintenance
Insulating Oil for Transformer and
DMM-01-02 0 04/2004
Switchgear
Earth Fault Indicator (EFI) Inspection &
DMM-01-03 0 05/2005
Testing
Field Test Techniques for Distribution
DMM-01-04 0 03/2005
Transformer
DMM-01-05 Maintenance of Substation Room 0 05/2005
DMM-02-01 Meter Inspection & Maintenance 0 12/2004
Ring Main Unit (RMU) Inspection &
DMM-02-02 0 04/2004
Maintenance
DMM-02-03 Distribution Panel Inspection & Maintenance 0 04/2004
Distribution Transformer Inspection &
DMM-02-04 0 04/2004
Maintenance
DMM-02-05 Minipillar Inspection & Maintenance 0 12/2004
DMM-03-01 Overhead Line Patrolling 0 12/2004
DMM-03-02 Overhead Line Maintenance 0 12/2005
Overhead Lines' S/S and Equipment
DMM-03-03 1 03/2005
Inspection & Maintenance
DMM-03-04 Pole Numbering System 0 12/2005
The Distribution Maintenance Manual (DMM-01-01) provides general guidelines for

the inspection and maintenance of substation equipment on distribution feeders rated
34.5 kV and below.
The Distribution Maintenance Manual (DMM-01-03) provides precise and adequate

information on the application, use, testing and maintenance of fault indicators in-
48

service on SEC MV distribution network. It includes also installation, fault

sectionalizing techniques and reporting malfunctioning of fault indicators .

information on Field testing, which has the primary objective of evaluating
serviceability of the distribution transformer when test conducted as per approved
standards. This Instruction Manual specifies the field tests recommended for
distribution transformers and defines the criteria for acceptability. The tests
recommended are applicable to in-service transformers.

information on the planned Inspection and Maintenance of MV/LV Meter
Installations. Meter Installations are required to be maintained regularly in order to
keep the meter installations up to SEC Standards to eliminate any potential hazards
present and to protect SEC from the losses incurred by meter errors developed after a
certain period of service.

information on the planned Inspection and Maintenance of 11/13.8 kV RMU
switchgear.
The scope of Distribution Maintenance Manual (DMM-02-05) is to set out a guideline

and procedure for inspection and maintenance of Mini-pillars in service in order to
achieve reliable performance and optimum service life.

information on the overhead network patrolling.

information on the maintenance of distribution overhead line feeders 34.5 kV and
below.
The (DMM-03-04) provides precise and adequate information on the pole numbering
system of MV O/H distribution feeders (34 .5 kV and below ).
49

7- SAFETY MANUAL FOR WORKING ON DISTRIBUTION NETWORK

http://sec2/dist_cust/dist/DistStandard/DSM/index.htm
NUMBER ,7( 0
' ( 6&5 , 3 7 , 2 1 REV. DATE
01- 01 Δϴ
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8- DISTRIBUTION PLANNING STANDARD (DPS)
The “Distribution Planning Standard” provides a guideline to the Planning Engineers
in the Saudi Electricity Company for the Planning of Distribution Network.
TABLE OF CONTENTS
1. DISTRIBUTION PLANNING CRITERIA
1.1 Introduction 1.7 Power Factor
1.2 Definitions 1.8 Voltage Fluctuation
1.3 General Principles 1.9 Standard Distribution Voltage
1.4 Frequency 1.10 Voltage Drop
1.5 Harmonics 1.11 Voltage Regulation
1.6 Phase Unbalance 1.12 Standard Loading Conditions
2. MEDIUM VOLTAGE PLANNING CRITERIA

2.1 Introduction
2.2 Design of M. V. Network
2.2.1 Contingency Plan Criteria
2.2.2 Grid Station Criteria
2.2.3 Feeders Configuration
2.2.4 Feeders Loading
2.2.5 Normal Open Point
50

2.3 Supply to Rural Area

2.4 Supply to Bulk Customer
2.4.1 Estimation of load
2.4.2 Voltage Drop Calculation
2.5 Mode of supply
2.5.1 Bulk LV Customers
2.5.2 Bulk MV Customers:
3. LOW VOLTAGE PLANNING CRITERIA

3.1 Introduction
3.2 Customer Classification
3.3 Estimation of Customer Load
3.4 Load Estimation Procedures
3.5 Low Voltage Network Design
3.5.1 Underground Network Configuration
3.5.2 Overhead Line Network Configuration
3.6 Calculation of Voltage Drop
3.7 Distribution Substation
3.7.1 Distribution Substation Type
3.7.2 Loading of Distribution Substations
3.7.3 Sites of Distribution Substation 3.7.4 Distribution Cabinet
3.8 Low Voltage Cables/Conductors
3.9 Reinforcement Of Low Voltage Network
3.10 New Plot Plan
4. IMPROVEMENT OF THE NETWORK PERFORMANCE

4.1 Introduction
4.2 Short Circuit Performance
4.3 Voltage Regulator Placement
4.4 Capacitor Placement
4.5 Motor Starting Voltage Dip
4.6 Auto-Reclosers
4.7 Loss Evaluation
51

B-TRANSMISSION STANDARDS
http:// e-dhq-webapp2/Tp- Reports/standards/ index/tssd_home.aspx
1. TRANSMISSION MATERIAL STANDARDS' AND SPECIFICATIONS

http://e-dhq-webapp2/Tp-Reports/standards/tmss.aspx
52

This Specification describes the general requirements applicable to all SEC

Transmission Material Standards' and Specifications (TMSS) for use in the
Transmission System of Saudi Electricity Company.
53

2. TRANSMISSION ENGINEERING SPECIFICATIONS

http://e-dhq-webapp2/Tp-Reports/standards/tes.aspx
3. TRANSMISSION CONSTRUCTION SPECIFICATIONS

http://e-dhq-webapp2/Tp-Reports/standards/tcs.aspx
54

Standard (TES-P-104-1) for U/G Power Cable Transmission Engineering Standard

provides general information applicable to underground cables and their applications
to the system of Transmission Chapters of TES -P-104 and the references therein serve
as a guide to the Design Engineer.
Standard (TES-P-104-2) has been prepared as a guide in the selection of applicable

types of insulated cables with copper or aluminum conductor tha t will be used for 110,
115, 132, 230 and 380 kV underground cable circuits in the Saudi Electricity
Company (SEC) Transmission Network .
Standard (TES-P-104-3) covers the selection of a specific type and size of power
cable based on particular applications and conditions in the system of Saudi Electricity
Company (SEC), Transmission Network .
Standard (TES-P-104-4) has been prepared as a guide for the splicing & termination
of insulated cables with copper or aluminum conductor that will be used for 110, 115,
132, 230 and 380 kV underground cable circuits in the system of Saudi Electricity
Company (SEC), Transmission Network .
Standard (TES-P-104-5) provides design considerations of cable installations for

direct buried or duct applications in the Transmission Network.
The purpose of the "Substation Design Standards" (TES-P-119) is to clearly define the
design philosophy and practices to enable the design engineer to develop cost effective
designs of SEC substations. This standard covers the primary transmission within the
voltage range of 110 kV to 380 kV.
The purpose of standard (TES-P-122-1) is to clearly define design philosophy and

practices adopted by SEC to enable the design engineer to develop cost effective
designs of SEC Transmission Lines. This standard: covers transmission lines for
110kV, 115 kV, 132kV, 230 kV and 380 kV systems.
55

C- CUSTOMER SERVICE MANUAL:

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ήΑ΃ϭ
ΔϴϧϼϋϹ΍ΕΎΣϮϠ ϟΔϴ΋ΎΑήϬϜϟ΍
ΔϣΪΨϟ ΍ϝΎ μϳ ·ΕΎΒϠσ
˻́ ˯ΎΑήϬϜϠϟ
Δϳ
ΩϮόδϟ΍
Δϛήθϟ΍
ϖϓ ΍
ήϤϟ
Δϴ ΋ΎΑήϬϜϟ΍
ΔϣΪΨϟ ΍
ϝΎ μϳ ·ΕΎΒϠσ
˻̂ ΐ Ϡ σήϴ ϴϐΗΪϬΟ
˻˺˹
ΓέΪϘϟ΍
βϔ ϨΑ
Ω΍ Ϊϋήϴ ϴϐΗΐ Ϡσ
Κϟ
ΎΜϟ
΍
Ϟμ ϔ
ϟ΍ ΔΘϗΆϤϟ΍
Δϴ΋ΎΑήϬϜϟ
΍ ΔϣΪΨϟ ΍ϝΎ μϳ ·ΕΎΒϠσ
˼˺ ˯ΎθϧϹ΍
ν ΍ ήϏϷ ΔΘϗ ΆϤϟ΍
Δϴ΋
Ύ ΑήϬϜϟ΍ ΔϣΪΨϟ ΍ϝΎμϳ ·
˼˻ ΕΎΒγΎϨϤϠϟ
ΔΘϗ ΆϤϟ΍
Δϴ΋
Ύ ΑήϬϜϟ΍ ΔϣΪΨϟ ΍ϝΎμϳ ·
56

ϊ Α΍
ήϟ΍
Ϟμ ϔϟ
΍ Ε΍Ω΍ Ϊόϟ΍
˽˺ Ε΍Ω΍ Ϊόϟ ΍ϭΕ΍ΪΣϮϟ ΍ΩΪϋΪϳ ΪΤΗ
˽˻ Ε΍Ω΍ Ϊόϟ΍ΐ ϴ ϛήΗ ϊϗ ΍Ϯϣ
˽˼ Ύ
ϬΗ΍˯΍ήΟ· ϞϤϜΘ δΗϢϟ ϭ ΔΒϛήϣ Ε΍Ω΍ Ϊϋϊϣ ϞϣΎ όΘ ϟ΍Δϴϔϴϛ
˽˽ ϞϴΠδΘϟ ΍
Ϧϋ Δϔ ϗϮΘϤϟ ΍Ε΍Ω΍ Ϊόϟ΍
ϊ ϣ ϞϣΎ όΘ ϟ΍Δϴϔϴϛ
˽˾ ϢϴϣήΘ ϟ΍
ϭ΃ ϡΪϬϟ ΍
ΐ ΒδΑ Ω΍Ϊόϟ ΍Δϟ΍ί·
˽˿ ΓΩϮϘ ϔ Ϥϟ΍Ε΍Ω΍ Ϊόϟ΍
ϊ ϣϞϣΎ όΘ ϟ΍Δϴϔϴϛ
˽̀ Δϴ
γΎ ϴ
ϗήϴϐϟ΍
ϊ σ΍ ϮϘϟ΍ϭΔϠτ όΘϤϟ ΍ϊ σ΍ ϮϘ ϟ΍
ϝ΍ ΪΒΘγ΍
ϊ ϣ ϞϣΎ όΘ ϟ΍Δϴϔϴϛ
β ϣΎ Ψϟ΍
Ϟμ ϔ
ϟ΍ Δϴ΋ΎΑήϬϜϟ ΍ΔϣΪΨϟ ΍ΓΩΎϋ·ϭ Ϟμ ϓ
˾˺ ΪϳΪδΘϟ ΍
ϡΪϋΐ ΒδΑ Δϴ ΋ΎΑήϬϜϟ ΍ΔϣΪΨϟ ΍ΓΩΎ ϋ·ϭ Ϟμ ϓ
˾˻ ϙήΘ θϤϟ ΍
ΐ Ϡ σ ϰϠ ϋ ˯Ύ
˱ ϨΑ
Δϴ ΋ΎΑήϬϜϟ ΍ΔϣΪΨϟ ΍
Ϟμ ϓ
˾˼ Δϴ
Ϥγήϟ ΍ΕΎϬΠϟ ΍ΐ ϠσϰϠ ϋ ˯Ύ
˱ ϨΑΎ ϬΗΩΎ ϋ·ϭ Δϴ΋ΎΑήϬϜϟ ΍ΔϣΪΨϟ ΍
Ϟμ ϓ
˾˽ Δϴ΋Ύ
ΑήϬϜϟ ΍Ε΍Ϊϳ ΪϤΘϟ΍˯Ϯγ ΐ ΒδΑ Δϴ ΋ΎΑήϬϜϟ ΍ΔϣΪΨϟ ΍
Ϟμ ϓ
˾˾ ϝΎϤΣϷ΍ ΓΩΎ ϳί ΐ ΒδΑ Δϴ ΋ΎΑήϬϜϟ ΍ΔϣΪΨϟ ΍
Ϟμ ϓ
˾˿ Ω΍Ϊόϟ΍Γ˯΍ήϗ Ϧϣ ϦϜϤΘϟ ΍ϡΪόϟ
Δϴ ΋ΎΑήϬϜϟ ΍ΔϣΪΨϟ ΍
Ϟμ ϓ
˾̀
ϖϓ ΍ήϤϟ΍ΔϳΎϤΣ ϡΎψϧ ΔϔϟΎΨϣ ΐ ΒδΑ Δϴ΋ΎΑήϬϜϟ ΍ΔϣΪΨϟ ΍Ϟμ ϓ
˾́ ϙϼϬΘγ ϻ΍ήϴΗ΍
Ϯϓ
ήϴ Ϗ ΕΎϘ ΤΘ δϣ ΩϮΟϭ ΐ ΒδΑ Δϴ ΋ΎΑήϬϜϟ ΍ΔϣΪΨϟ ΍
Ϟμ ϓ
˾̂ ϙϼϬΘγ΍ ϞΠδΗ ϻ ϲΘϟ ΍
Ε΍Ω΍ Ϊόϟ ΍Ϧϋ Δϴ ΋ΎΑήϬϜϟ ΍ΔϣΪΨϟ ΍
Ϟμ ϓ
˾˺˹ Δϛήθϟ ΍
Ε΍Ϊόϣ ϝϼϐΘγ΍ ΐ ΒδΑ Δϴ ΋ΎΑήϬϜϟ ΍ΔϣΪΨϟ ΍
Ϟμ ϓ
˾˺˺ ϙήΘθϤϟ΍ϞΒϗϦϣ ΔϣΪΨϟ ΍ΓΩΎϋ· έ΍ήϜΗ ΐ ΒδΑ Δϴ΋ΎΑήϬϜϟ ΍ΔϣΪΨϟ ΍Ϟμ ϓ
˾˺˻
Ϊϴϔ
ΘδϤϟ
΍
ΐ ϠσϰϠ ϋ˯Ύ
˱ ϨΑς γ ϮΘϤϟ΍ς ϐπ ϟ ΍ΕΎϜΒθϟ Δϴ΋ΎΑήϬϜϟ ΍ΔϣΪΨϟ ΍
Ϟμ ϓ
α ΩΎ δϟ΍
Ϟμ ϔ
ϟ΍ Δϔ ϳήόΘ ϟ
΍
˿˺ Δϴ΋Ύ ΑήϬϜϟ ΍ΔϗΎτϟ ΍
ϊϴ ΑέΎ όγ΃ ΔϔϳήόΗ
˿˻ ΓέϮΗΎ ϔϟ
΍Ω΍ Ϊϋ·ϭ Ω΍Ϊόϟ΍Δϧ Ύϴ
λ ϭ Γ˯΍ήϗ ΔϔϳήόΗ
˿˼ ΓΪϳ ΪΠϟ ΍ΕΎΒϠ τϠ ϟ
ϝΎ μϳ Ϲ΍ Δϔ ϳ
ήόΗ
˿˽ ϊϴϤΠΘϟ ΍
ϭ Δ΋ΰΠΘϟ ΍ϭΔϳϮϘ Θϟ΍ϭ ΔϓΎο Ϲ΍ ΕΎΒϠσ ϝΎ μϳ ·Δϔ ϳήόΗ
˿˾ Ω΍ΪϋϥϭΪΑ Γήϴ ϐμ ϟ ΍
ϝΎ ϤΣϸϟ Δϴ ΋ΎΑήϬϜϟ ΍ΔϣΪΨϟ ΍ϝΎ μϳ · ΔϔϳήόΗ
˿˿ Ϧϴ ϣ΄Θϟ ΍ϡϮγέ
˿̀ Ϧϴ
ϣ΄Θϟ
΍
ϡϮγ έϭΔϔ
ϳήόΘϟ
΍
ΔϤϴϗ
Ϟϴμ ΤΗ
˿́
ϦϴϛήΘ
θϤϟ΍ϦϣΔΑϮϠ
τ Ϥϟ
΍
ΔϴϠ
όϔϟ
΍
ϒϴ ϟ
ΎϜΘϟ
΍
˿̂
ϯήΧ΃
ϡϮγέ
˿˺˹ ϦϴϛήΘθϤϠϟ
ώϟΎ
ΒϤϟ΍
ΓΩΎϋ·
˿˺˺
ϙϼϬΘγϻ΍
Δϔϳ
ήόΘϟ
ϲΨϳέΎΘϟ΍
ϞΠδϟ ΍
ϊ ΑΎ
δϟ΍
Ϟ˰
μϔϟ
΍
ΔϣΎ
όϟ΍
ϖϓ΍ήϤϟ΍
ΔϳΎϤΣ
̀ ˺ Δϛήθϟ΍ΕΎϜϠΘϤϣϑϼΗ ·
Ι Ω΍ϮΣ
̀ ˻
Ε΍Ω΍
Ϊόϟ
ΎΑΔϘϠόΘ
Ϥϟ΍
ΕΎ ϣ΍ήϐϟ
΍ϭ ΕΎϔϟΎΨϤϟ΍
ϦϣΎ
Μ ϟ΍
Ϟμ ϔ
ϟ΍ ήϴΗ΍Ϯϔϟ΍
Ϟϴμ ΤΗϭέ΍Ϊλ ·ϭ Γ˯΍ήϗ
́ ˺ Ε΍Ω΍Ϊόϟ΍
Γ˯΍ ήϗ
́ ˻
ήϴΗ΍
Ϯϔϟ ΍
ϊϳί ϮΗϭέ΍Ϊλ ·
́ ˼
ϙϼϬΘ γ ϻ΍
ΏΎ δΣ Δϴϔϴϛ
57

́ ˽
ϙϼϬΘ γ ϻ΍ ήϴΗ΍ ϮϓώϟΎΒϣϞϴμ ΤΗ
́ ˾ ήϴΗ΍Ϯϔϟ ΍
Ϟμ ϓϭ ϊϴ ϤΠΗ
́ ˿ ϙϼϬΘγ ϻ΍
ήϴΗ΍Ϯϓ ΔϤϴ ϗϞϴμ ΤΗ ϞϴΟ΄Η
́ ̀
Γ˯΍ήϘϟ
΍˯ΎτΧ΃ ΔΠϴ Θϧ ήϴ Η
΍Ϯϔϟ ΍
΢ϴΤμ Η
́ ́ ΓέϮΗΎϔϟ΍ϲϓ Ϛϟ Ύ
Ϥϟ΍Ϣγ ΍
ήϴϴ ϐΗ
́ ̂ Δϴϋήϔϟ ΍Ε΍ Ω΍Ϊόϟ΍
Γ˯΍ ήϗϡΎψϧ
́ ˺˹
ϙϼϬΘγϻ΍ήϴ
Η΍
ϮϔΑ
Δλ Ύ
Ψϟ΍
ϦϴϛήΘθϤϟ ΍
ϱϭΎ Ϝη ϊ ϣϞϣΎ όΘ
ϟ΍Δϴϔϴϛ
ϊγΎΘ ϟ΍
Ϟμ ϔ
ϟ΍ Δϴ
Ϩϔ
ϟ΍
˯Ύ
τ ΧϷ΍
ϭϝΎ
τ ϋϷ΍
ΔΠϴΘϧ
Ϧϴ
ϛήΘθϤϟ΍
ήϴΗ΍Ϯϓ
ΕΎϳ ϮδΗϭ Ε΍Ω΍ Ϊόϟ΍
κ Τϓ
̂˺ Ύ
ϬΘϣϼγ Ϧϣ Ϊϛ΄ΘϠϟΕ΍Ω΍ Ϊόϟ΍
κ Τϓ
̂˻ ϙήΘθϤϟ΍
ΐ Ϡ σϰϠϋ˯Ύ ϨΑΕ΍Ω΍ Ϊόϟ΍
κ Τϓ
ήηΎ
όϟ ΍
Ϟμ ϔ
ϟ΍ Ε΍ΪόϤ ϟ΍
ϭΕ΍Ω΍ Ϊόϟ΍ϞϘϧ
˺˹˺
Ε΍ΪόϤϟ ΍
Ε΍Ω΍ Ϊόϟ΍ϞϘϧβ γ΃
D- CRAFT CERTIFICATION MANUALS

OVERVIEW
The Craft Certification System is a systematic program for the certification of well-
trained and qualified Saudi craftsmen and Telecommunications Operations/
Maintenance Technicians (TOT/TMT) for Grade Code 45 through 48 and is used as
an example. The system is implemented by the Craft Certification Manual produced
for each craft included in this certification system. The Craft Certification Manual
consists of three volumes contained within a single binder:
Volume I Administrative Guidelines-I

Appendix-A On-the-Job Training (OJT) Program Example Forms
Appendix-B On-the-Job Training (OJT) Program Forms
Appendix-C Craft Certification Training Program (TOT) Example Forms
Appendix-D Craft Certification Training Program (TOT) Forms
Appendix-E Craft Certification Training Program (TMT) Example Forms
Appendix-F Craft Certification Training Program (TMT) Forms
Appendix-G Master Duty/Task Matrix (TOT/TMT)
Appendix-H Equipment/Test Equipment/Tool List (TOT/TMT)
Volume II Administrative Guidelines-II

Appendix-A On-the-Job Training (OJT) Program
Appendix-B Technical Career Development Program (TOT) (GC 45-1)
Appendix-C Technical Career Development Program (TMT) (GC 45-1)
Volume III Administrative Guidelines-III

Appendix-A Technical Career Development Program TOT (GC 46)
Appendix-B Technical Career Development Program TOT (GC 47)
58

Appendix-C Technical Career Development Program TOT (GC 48)

Appendix-D Technical Career Development Program TMT (GC 46)
Appendix-E Technical Career Development Program TMT (GC 47)
Appendix-F Technical Career Development Program TMT (GC 48)
Appendix-G Technical Career Courses TOT/TMT (GC 45-48)
The Administrative Guidelines in Volume I describe the Craft Certification System
in detail, including the contents and scope of each volume. It is intended as a guide to
Sample Forms used for the On-the-Job Training and Career Development Programs in
Volumes II and III, respectively. It also includes the Career Progression and
Training Matrix classifying the courses to be taken with Training and Education
Department (TED), Field or Vendor for craft certification in Grade Codes 45 through
48.
The On-the-Job Training Manual, Volume II, contains general information and the
technical training requirements for the On -the-Job Training Program. It is intended to
guide the training and qualification of OJT trainees for craft certification in Grade
Code 45-2 status. It is also the source for the contents of a personal On-the-Job
Training Manual to be issued to each trainee. This personal training manual for the
trainee should contain the following items:
1. The section of this manual entitled, “On-the-Job Training (OJT) Program” to

inform the trainee about the program and his responsibilities in Grade Code 45-2
status.
2. The trainee’s Overall On-the-Job Training Plan, Form 1A to establish all of the
training requirements listing OJT Assignments/Tasks and their duration.
3. All applicable OJT Tasks Progression, Forms 2A to identify all of the required
OJT assignment tasks and task steps associated with Task Repetition/Percentage
completed required for certification.
4. All applicable Task Qualification Cards (TQCs) to provide all required TQCs in
Grade Code 45-1 status.
5. A Task Qualification Summary , Form CCM 4A showing all required
training. When maintained current this will provide a ready reference to the
trainee’s progress.
59

6. The Craft Certification, Form CCM 5A to provide a record of Craft Certification

when the trainee has successfully completed the Craft Certification Evaluation.
7. A separate section to provide for any special instructi ons to the trainee .
The Technical Career Development Manual, Volume III, contains general information
and the technical training requirements for craft certification in Grade Codes 46
through 48. It is intended as a guide for the training and qualification of craft
employees. It is also the source for the contents of a personal Technical Career
Development Manual issued to each trainee.
ADMINISTRATIVE GUIDELINES-I
1. INTRODUCTION TO THE CRAFT CERTIFICATION MANUAL
1.1 Purpose and Scope
The Craft Certificat ion Manual documents the SEC-EOA Craft Certification
System. The Craft Certification System ensures that technicians are:
∑ Qualified
∑ Certified
on the individual job tasks performed at SEC-EOA Telecommunications

Division and ultimatel y certi fied for thei r jobs. Qual ifyi ng and certi fyi ng
technici ans ensure that they have demonstrated proficiency before advancing to
the next higher Grade Code.
This Craft Certification Manual will be used by the Operational Organizations and by
Training and Education Department (TED) personnel involved in the qualification and
certification of technicians. Specifically, Telecommunications Division
Superintendents, Assistant Division Superintendents, Supervisors/Foremen,
designated Craftsman Trainers and Craft Evaluators, OJT Analysts, Senior
Training Coordinator, Division Training Coordinator and the technicians all have a
role in the process and will use this manual.
60

This manual describes two programs. The first is the On-the-Job Training Program
(OJTP) for Grade Code 45- 02 Status trainees engaged in full -time training. This is a
full-time mentor program, which means, that the trainee is in close contact with his
mentor (Qualified Technician Trainer) for three (3) years. The goal is to compl et e
al l trai ni ng and to qual ify on al l tasks per formed b y Tel ecommuni cat ions
Operations/Maintenance Technician IV (GC 45). The trainee accomplishes task
qualification and certification in the workplace. The On-the-Job Training Program for
Telecommunications Operations/ Maintenance Technician is administered by the
Telecommunications Division in direct association with the SEC-EOA Central
Training Institute (TED), Job Skills Training Division (JSTD) and On-the-Job
Training Administration Unit (OJTAU).
The second program is the Technical Career De velopment Program (TCDP) .

This program is for regular full-time employees in Grade Code 45-01 Status who are
seeking Craft Certification in Grade Codes 46-48. It is not a full-time training program
because the technician must also perform a full complement of assigned job
activities. The goal is to certify technicians to perform tasks for the next hi gher
job before they are promot ed. Techni cians are trained on the job within the
operation organization under the guidance of a qualified Technician Trainer.
They also attend Off-the -Job Training consisting of technical and non-technical
courses sponsored by TED. A technician becomes qualified on each task based on
an independent evaluation of his task performance. After qualifying on all
tasks, a technician beco mes craft certified based on an evaluation by a
Certification Committee. The committee reviews training completed and
evaluates the technician’s job knowledge and abilit y to perform job tasks.
1.2 Description of Each Volume

The Craft Certification Manual (CCM) consists of three volumes contained within a
single binder. Division -specific manuals are issued as required.
Vo lu me I: Administrative Guidelines
This describes the Craft Certification System purpose and benefits and how the system
61

fits into the job family of Telecommunications Operations/Maintenance Technicians’

Technical Career Development Pat h (TCDP). A career Progressi on and
Trai ning Mat rix shows the requi rement s for career advancement. Volume I
describes the roles and responsibilities of personnel involved in Craft
Certification and presents Job Profiles for the Telecommunications
Operations/Maintenance Technician job famil y. It also describes how personnel
will implement the certification programs and use the required administrative
forms.
Volume II: On-the-Job Training Manual

This is used to qualify 02-Status trainees on job tasks performed by a
Telecommunications Operations/Maintenance Technician IV (GC 45). It contains an
introduction to the Craft Certification System, a duty task list, all of the Task
Qualification Cards (TQCs) and Telecommunications Division-specific information
and supporting data. A personal version of the On-the-Job Training Manual
containing the applicable training requirements will be issued to each trainee. It will
contain all of the information necessary for the trainee to understand and accomplish
his training plan.
Volume III: Technical Career Development Manual

This is used to qualify full-time Telecommunications Operations/Maintenance
technicians for Grade Codes 46-48. It contains an introduction of the Craft
Certification System, duty task lists, all of the required Task Qualification Cards
(TQCs) and Telecommunications Division-specific information and supporting data.
A personal version of the Technical Career Development Manual will be assembled
for each Telecommunications Operations/Maintenance Technician. A summary of the
contents of each volume is shown in Table 1
62

Table 1 Contents of Craft Certification Manual
Vol ume I Vol ume I I Vol u me I II

Overview of Craft Certification System Overview of Craft Certification Overview of Craft Certification System
Administrative Guidelines-I System Administrative Guidelines-III
∑ TC Progress'n and Train'g Matrix Administrative Guidelines-II ∑ Craft Certification Purpose and
∑ Career Development Path ∑ Craft Certification Purpose and Scope
∑ How to Conduct the CC Process Scope ∑ TC Progress'n and Train'g Matrix
∑ Roles and Responsibilities ∑ TC Progress'n and Train'g ∑ Career Development Path
∑ TOT/TMT Job Profiles Matrix ∑ Craft Certification Process
∑ Forms and Records ∑ Career Development Path ∑ Craft Certification Evaluation
∑ Glossary ∑ Craft Certification Process ∑ Trainee’s Progress
∑ Craft Certification Evaluation ∑ Trainee’s Responsibilities
Appendix- A OJT Example Forms ∑ Trainee’s Progress ∑ Training and Certification Forms
Appendix-B OJT Forms
∑ Trainee’s Responsibilities ∑ TC Development Program GC 46-
Appendix-C CC (TOT) Example Forms
∑ Training and Certification 48:
Appendix-D CC (TOT) Forms
Forms
Appendix-E CC (TMT) Example Forms Appendix-A TCD-TOT (GC 46)
∑ On-the-Job Training Program
Appendix-F CC (TMT) Forms Appendix-B TCD-TOT (GC 47)
Appendix-G Master Duty/Task Matrix Appendix-A OJT Program Appendix-C TCD-TOT (GC 48)
(TOT/TMT) Appendix-B TCD-TOT (GC 45- Appendix-D TCD-TMT (GC 46)
Appendix-H Equip/Test Equip/Tool List 1) Appendix-E TCD-TMT (GC 47)
(TOT/TMT) Appendix-C TCD-TMT (GC 45- Appendix-F TCD-TMT (GC 48)
1) Appendix-G TC Courses TOT/TMT
(GC 45-48)
Appendix-H Abbreviations Index
ADMINISTRATIVE GUIDELINES-II
1.1 Craft Certification System Purpose and Scope
SEC-EOA is committed to developing well-trained, competent Saudi craftsmen. The

Craft Certification System was established to ensure that Telecommunications
Technicians and other craftsmen would receive formal training to qualify on technical
tasks and become certified for each level within a craft job family.
This Craft Certification System consists of two distinct but related programs. The first
is the On-the-Job Training Program. This is a full-time mentor program, which means
63

that the trainee is in close con tact with his mentor ( Qualified Craftsman Trainer). The
goal is to complete training and become certified to perform Telecommunications
Technician IV job tasks. Trainees at GC 45-2 status must satisfactorily complete the
OJT assignment tasks and TQCs relev ant to GC 45-1 Duties in Volume II, Appendix-
B/C to be eligible for job certification. The Program is administered by the
Information Technology and Communications (IT&C) in association with the SEC-
EOA Central Training Institute (SECTI), Job Skills Traini ng Division (JSTD) and On-
the-Job Training Administration Unit (OJTAU).
The second program is the Technical Career Development Program (TCDP), which is
for employees in grade codes 46, 47 and 48, who will be trained part time On-the-Job
in conjunction with regular work assignments. As shown in Table 1, the Career
Progression and Training Matrix, lists the standard Career Progression, Training, and
Certification requirements applicable to this program.
A comprehensive Craft Certification Manual has been developed to implement these

two programs. The Manager, Training and Education Department, SECTI issue it. The
purpose of Volume II of the Craft Certification Manual is to enable a trainee to
understand the Craft Certification System and his responsibilities in the program.
More importantly, it also contains the training assignments and guidance needed to
complete training and qualification for Telecommunications Technician IV (GC 45).
The OJT Program in Volume II of the Craft Certification Manual is organized in
Appendices A-C, as follows:
OJT Assignment List
Appendix-A OJT Assignment/Task List
Overall OJT Plan, Form 1A, TOT/TMT IV (GC 45-2)
OJT Assignment/Task/Duration
Task Progression, Form 2A
Appendix-B Duty List TOT IV (GC 45-48)
Duty/Task List TOT IV (GC 45-1)
Training and Craft Certification Plan, CCM 1A
Duty/Task/Duration/Associated Technical Courses
Task Progression, Form 2A
Task Qualification Cards (TQC), CCM 2A
Equipment/Test Equipment/Tool List TOT (GC 45-1)
64

Appendix-C Duty List TMT IV (GC 45-48)

Duty/Task List TMT IV (GC 45-1)
Training and Craft Certification Plan, CCM 1A
Duty/Task/Duration/Associated Technical Courses
Task Progression Form 2A
Task Qualification Cards (TQC), CCM 2A
Equipment/Test Equipment/Tool List TMT (GC 45-1)
An analysis of the Telecommunications technician job family at SEC-EOA

Information Technology and Communications (IT&C) has identified the technical job
duties and the associated tasks and task steps performed by Telecommunications
Technicians for Grade Codes 45-48.
A task is a distinct work activity that produces a complete work product or service.
Keep in mind that each duty will consist of one or more tasks and, in turn, each t ask
will require the performance of several task steps.
A Task Qualification Card (TQC) has been developed for each job task contained in a
Duty and Task List produced as a result of the job analysis. A TQC describes the
individual steps for performing the task and the standards to which it must be
performed. In the Craft Certification System, the trainees must qualify on each task
covered by a TQC.
ADMINISTR ATIVE GUIDELINES-III
1.1 Craft Certification System Purpose and Scope
SEC-EOA is committed to developing well-trained, competent Saudi craftsmen. The

Craft Certification System was established to ensure that Telecommunications
Technicians and other craftsmen would receive formal training to qualify on technical
tasks and become certified for each level within a craft job family.
This Craft Certification System consists of two distinct but related programs. The first
is the On-the-Job Training Program. This is a full -time mentor program, which means
that the trainee is in close contact with his mentor ( Qualified Craftsman Trainer). The
goal is to complete training and become certified to perform Telecommunications
65

Technician IV job tasks. The Program is administered by the Telecommunications

Department (IT&C) in association with the SEC-EOA Central Training Institute
(SECTI), Job Skills Training Division (JSTD) and On-the-Job Training
Administration Unit (OJTAU).
The second program is the Technical Career Development Program, which is for
employees in grade codes 46, 47 and 48, who will be trained part time On-the-Job in
conjunction with regular work assignments. As shown in Table 1, the Career
Progression and Training Matrix, lists the standard Career Progression, Training, and
Certification requirements applicable to this program.
A comprehensive Craft Certification Manual has been developed to implement these

two programs. The Manager, Training and Education Department, SECTI issues it.
The purpose of Volume III of the Craft Certification Manual is to enable a trainee to
understand the Craft Certification System and his responsibilities in the program.
More importantly, it also contains the training assignments and guidance needed to
complete training and qualification, for Telecommunications Operations/Maintenance
Technician III, II and I (GC 46-48).
The Volume III of the Craft Certification Manual is organized in Appendices A-F,
providing Telecommunications Area specific information and data to support training
in Telecommunications Operations/Maintenance Technician jobs, as follows:
Appendices A-F contain the following job specific items:

Duty List TOT/TMT (GC 45-48)
Duty/Task List TOT/TMT (GC 45-48)
Training and Craft Certification Plan, Form CCM 1A

Duty/Task/Duration, TOT/TMT (GC 45-48)
Duty/Task/Duration, TOT/TMT (GC 45-48), Associated Technical Courses
Task Progression, TOT/TMT (GC 45-48), Form 2A
Task Qualification Cards (TQC), TOT/TMT (GC 45-48), Form CCM 2A/B
Equipment/Test Equipment/Task List, TOT/TMT (GC 45-48)
66

An analysis of the Telecommunications Operations/Maintenance Technician job

family at SEC-EOA telecommunications department has identified the technical job
duties and the associated Tasks/Steps performed by Telecommunications Technicians
for Grade Codes 45-48. A task is a distinct work activity that produces a complete
work product or ser vice. Keep in mind that each duty will consist of one or more tasks
and, in turn, each task will require the performance of several task steps. A Task
Qualification Card (TQC) has been developed for each job task contained in a duty
and task list produced as a result of the job analysis. A TQC describes the individual
steps for performing the task and the standards to which it must be performed. In the
Craft Certification System, the trainees must qualify on each task covered by a TQC.
67

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68

LESSON 1.3
GENERATIORS AND EXCITATION

SYSTEM
69

70

LESSON 1.3
GENERATIORS AND EXCITATION SYSTEM
LESSON OVERVIEW
DESCRIPTION
Lesson 1.3 on generators and Excitation System includes Stator, Rotor, Bearings,
Lubrication System, Thermocouples, Seal Oil System, Main Leads, Current
Transformers, Neutral Grounding Transformer and Resistor-Temperature Detectors
(RTD), Generator Frame, Generator Cooling, Hydrogen Blower and Cooler,
Hydrogen Gas System, Gland Seals System. The Excitation System is discussed
covering Brush and Slip Ring Excitation, Brushless Excitation with Parallel Operation
of Generators.
The lesson concludes with Preventive Maintenance.
OBJECTIVES
Upon completion of this lesson, the participants should be able to:

∑ Familiarize with Power Plant generators and their operation.
∑ Identify generator components and their functional characteristics including Stator,
Rotor, Bearings, Lubrication System, Thermocouples, Seal Oil System, Main
Leads, Current Transformers, Neutral Grounding Transformer and Resistor-
Temperature Detectors (RTD), Generator Frame, Generator Cooling, Hydrogen
Blower and Cooler, Hydrogen Gas System, Gland Seals System.
∑ Familiarize with Excitation Systems including Brush and Slip Ring Excitation,
Brushless Excitation with Parallel Operation of Generators.
∑ Perfornm and supervise Preventive Maintenance of generators in Power Plants.
Task 1.3-1: Operation of Polyphase generators using Power System Simulator
71

72

INTRODUCTION
AC generators (Alternators)are the productionpoints of electricalenergy with nominal
frequency and voltage. Alternators are driven by turbines (SteamGas),
or as shown in Fig.
1.3-1.
Fig. 1.3-1 Steam Turbine
As the magnetic field needed for electricity production is created by applying

DC voltage on the rotor winding terminals , this DC voltage is generated by the Exciter.
This is the core of most of our electrical power plants where all electricity is generated
except in electrochemical systems (batteries, photovoltaic cells etc).
The majority of electrical energy is generated in power plants by synchronous

machines; as shown in Fig. 1.3-2. These may be three phase synchronous Generators,
the term synchronously (in time) with the stator rotat ing field.
73

Fig. 1.3-2 Power Plant Generators
THEORY OF OPERATION
The AC Generator is a synchronous Alternator with revolving field. The required

magnetic field is produced by DC electromagnets, which are excited by a small DC
Generator (Exciter). As shown in Fig. 1.3-3, a simplified configuration of the AC
Generator and Exciter is given with the wave shape of the generated voltage on the
Generator terminals.
The Electro-Magnetic Force (EMF) is

generated as each field coil sweeps past
the stator coil (Armature) and as each coil
passes in front of a stator winding
produces an alternating voltage with Fig. 1.3-3 Simplified AC Generator
frequency (f) that depends on speed of rotation (n) and number of poles (p) of the
Alternator.
74

pn
f= Hz
120
Where: N = Speed of rotatio f = Cycle per second (Hertz)
p = Total number of magnetic poles
A three-phase Generator has three separate but identical armature windings that are
acted on by one system of rotating magnets. Each winding, called a phase, consists of
a set of armature coils.
GENERATOR COMPONENTS
STATOR
All synchronous generators have the same type of stator winding. This is wound in the
slots of the laminated core, as shown in Fig. 1.3-4. The stator is supported on flexible
mountings within the frame.
Fig. 1.3-4 Stator
75

ROTOR
The construction of the rotor depends on the speed of the prime mover (Steam or Gas
Turbine) and the frequency and rated power of the Generator.
At low speed of rotation (large pole) rotor

with salient pole such as at hydroelectric
power station are used, as shown in Fig.
1.3-5. Most power station generators have
cylindrical rotor with speed of rotation
3600 rpm at network frequency of 60 Hz,
as shown in Fig. 1.3-6(a).
Fig. 1.3-5 Salient Pole Rotor
The rotor is supported on bearings installed in bearing brackets installed at each end of
the Generator Frame.
76

Fig. 1.3-6(a) Synchronous Generator Rotor
Fig. 1.3-6(b) shows the equivalent circuit of synchronous Generator.
Fig. 1.3-6(b) Equivalent Circuit of Synchronous Generator
77

GENERATOR FRAME
The Generator frame is fitted with gland seal assemblies around the rotor where it
penetrates the frame. These seals enable the frame to
provide a gas tight enclosure around the
stator and rotor. The enclosure needs to be gas tight because modern Turbine generators
usually have some form of internal Hydrogencooling system,as shown in Fig. 1.3-7.
The Generator frame, sometimes

called the housing, not only
supports the rotor and stator but
also provides a gas tight
environment to contain the
Hydrogen gas. In addition, the
frame houses the Hydrogen
coolers that cools the gas before it
is re-circulated through the
Generator.
Fig. 1.3-7 Generator Frame
The Generator frame also

includes the main lead box, as
shown in Fig. 1.3-8.
Fig. 1.3-8 Main Lead Box
78

BEARINGS
The bearings are electrically insulated from the frame in order to prevent any stray
currents from the rotor sparking between the journal and the bearing surfaces. This type
of sparking, called arcing, could damage thebearing surfaces.
Each bearing bracket assembly

also contains a gland seal
assembly. Gland seal assemblies
are mounted on the inner surface
of each bearing bracket and are
arranged around the rotor to help
keep the Hydrogen within the
frame. Outer oil seals also
mounted on the bearing brackets,
keep the lubricating oil inside the
bearing cavity, as shown in Fig.
1.3-9(a). Fig. 1.3-9(a) Generator bearing
LUBRICATION OIL SYSTEM
The lubrication oil system keeps the bearings of the turbine, Generator and exciter
supplied with lubricating oil (lube -oil). The system also provides oil for other moving
parts. The main oil pump is on the rotor shaft. The main oil pump circulates the
lubricating oil throughout the turbine system.
THERMOCOUPLE
The thermocouple is commonly used with DC meter movements to measure

alternating currents or voltages. The thermocouple is a very simple source of
electricity. When the junction between two unlike metals is heated, an emf is
generated between the unheated ends. While all metals and alloys will produce an emf
in this way, certain combinations, such as antimony and bismuth, copper and
constantan, iron and copper nickel alloy, produce a greater voltage for the same
amount of temperature difference, as shown in Fig. 1.3-9(b).
79

Fig. 1.3-9(b) Thermocouple Instrument
CURRENT TRANSFORMERS
Under the stator frame, there are current

transformers, as shown n Fig. 1.3-10.
These transformers provide current for
protective relaying, switching and
metering. The voltage regulator and
exciter are also supplied by the current
transformers.
Fig. 1.3-10 Current Transformer
NEUTRAL GROUNDING RESISTORS

Power-ohm Neutral Grounding Resistors are used in industrial power systems for
resistance grounding of WYE connected generators and transformers. A neutral
grounding resistor limits the fault current to a value, which is sufficient enough to
operate protective relays, yet prevent unwanted fault damage, as shown in Fig. 1.3-11.
80

Fig. 1.3-11 Neutral Grounding Resistors
GENERATOR COOLING
There are two cooling systems used in the Generator:
∑ Hydrogen Cooling System (for Stator)
∑ Air Cooling System (for Exciter)
Small generators usually below 30 Mega-Watts are cooled by circulating air through
the rotor and stator.Units that are rated between 30 and 200 Mega-Watts are cooled by
circulating Hydrogen between the rotor and stator. This type of cooling is called
Conventional Hydrogen Cooling. Units larger than 200 Mega-Watts are cooled by
circulating Hydrogen through hollow passages inside the stator coils.This is called Inner-
Cooling.
81

HYDROGEN COOLING SYSTEM
The windings inside the stator and on the rotor shaft develop a lot of heat as electric
current flows through them. The heat can damage the rotor windings or the stator
stacks. To prevent heat damages, a co oling medium circulates through the stator. This
keeps the temperature from getting too high. In the stator, the cooling medium is
Hydrogen gas. To remove heat from the components inside the Generator; the
Hydrogen is circulated around the hot components. Fig. 1.3-12(a) shows the flow path
of Hydrogen inside the Generator casing with four Hydrogen coolers with Oil seals
sealing each end of the rotor, two circulating fans and the stator. The arrows in the
illustration indicate the direction of the Hydrogen flow. The fans at each end of the
rotor blow the Hydrogen around the hot components. The heat absorbed by the
Hydrogen is then removed by cooling water flowing through the coolers.
Hydrogen gas coolers (Heat Exchangers) control the temperature of the circulating
Hydrogen. Hydrogen is cooled by water that passes through the finned tubes in the
coolers. In each section, the cooling water enters the inlet water chamber, flows
through the finned tubes in the cooler, changes direction in the return-water chamber at
the top and then leaves the cooler at the bottom. Hydrogen is passed through the cooler
by the blower.
Fig. 1.3-12(a) Flow Path of Hydrogen inside Generator
82

HYDROGEN BLOWER AND COOLER
Generator cooling is needed to remove the heat energy produced by the large currents
flowing through the conductors. This includes the direct current flowing though the
rotor windings as well as the alternating current being induced in the stator coils.
Another source of heat within the

Generator is the windage caused by the
spinning rotor. To remove this excess
heat energy, Hydrogen gas is circulated
through the Generator by a blower
attached to one end of the rotor,as shown
in Fig. 1.3-12(b).
Fig. 1.3-12(b) Hydrogen Blower
Hydrogenis used as a cooling medium because of its excellentheat absorbing capabilities,

and also because it is significantly
lighter than air and requires much less energy
to force it to
flow though the Generator
The Hydrogen that has picked up the excess

heat energy from the rotor and stator is
directed by the blower through the coolers
that are mounted in the Generator frame. As
it passes around the water tubes in the
coolers, the gas temperature is reduced. Once
cooled, the gas is recirculated to the stator
and rotor, as shown in Fig. 1.3-13. From the
coolers, some of the cold Hydrogen is forced
through the channels in the rotor. It usually Fig. 1.3-13 Hydrogen cooler
enters at both ends of the rotor and exits in
the middle.
83

The rotor windings are actually hollow to allow

the Hydrogen to flow through them to absorb
the heat energy. Hydrogen is also used to cool
the stator core. In radially cooled models,
Hydrogen flows along the outside of the stator,
and then inward, across the body of the stator,
Fig. 1.3-14 Radially Cooled Stator
as shown in Fig. 1.3-14
HYDROGEN GAS SYSTEM
∑ There is one distinct advantage to using Hydrogen as a cooling gas. Combinationsof

between5% and 70% of Hydrogen in air highly explosive
.
∑ The way to overcome this disadvantage is to avoid mixing the Hydrogen and air
together.
∑ Before any Hydrogen is pumped into thegenerator, the air is removed first bypurging
carbon dioxide.
∑ Carbon dioxide is non reactive gas that can be safely mixed with air in any
combination.
∑ The carbon dioxide is pumped into the bottom of the Generator. As it fills the
Generator frame, it pushes the air to the top. This air is removed by a piping
arrangement that vents the air to the atmosphere outside the building
.
∑ When the Generator is full of carbon dioxide,

it issafe to pump in the Hydrogen,since the
Hydrogen is so light; it is pumped into the top of the Generator. This way, the
Hydrogen gas will float on top of carbon dioxide and push it out through vents in the
bottom of the Generator as all of the internal cavities are
filled with Hy
drogen.
∑ During operation, Hydrogen is kept from mixing with outside air by the glandseal or
seal oil system.
84

∑ Before opening the Generator to the atmosphere for inspection or maintenance,

it is again
purged with carbon dioxide, this time to remove the Hydrogen.During this operation,
the Hydrogen is vented to the atmosphere outside the power plant.
∑ The Hydrogen gas system controls the safe handling of the Hydrogen that is used to cool
the Generator. It also provides a means of monitoring and maintaining the Hydrogen
condition during operation,
as shown in Fig. 1.3-15.
∑ The system functions include filling and emptying the Generator cavities, as already
described;maintainingand indicating the pressure, density
and purity ofthe Hydrogen
within the Generator; indi cating the presence of liquid in the Generator and finally
drying the Hydrogen and removing water vapor from theGenerator.
Fig. 1.3-15 Hydrogen Gas System
∑ The Hydrogen gas system consists of the gas

supplies, both Hydrogen
and carbondioxide.
The Hydrogen equipment group, which monitors the condition of Hydrogen, makes
sure that the system is operating at its peak efficiency. The Generator condition
monitoring unit detects thermal breakdown of the electrical insulation in the
Generator coils and finally
, the gasdrier driesthe Hydrogen and removeswatervapor from
the Generator.
85

∑ Another unit closely related to the

Hydrogen gas system is the Generator
auxiliaries, control enclosure housing
the various controls, monitors, alarms
and indicators for all of the auxiliary
systems,as shown Fig. 1.3-16.
Fig. 1.3-16 Generator auxiliaries control
SEAL OIL SYSTEM AND GLAND SEALS

The gland seals in the Generator are part of the seal oil system. These seals help prevent
Hydrogen leaking out of the Generator while
minimizing the amount of air and moisture that
can leak into the Generator.
∑ The seals are located around the rotor shaft where it penetrates the Generator bearing
brackets.These oil type gland seals are mounted inside the Generator inboard of the
rotor bearings.
∑ The function of the seal oil sy
stem is to supplyoil to these gland seals, both to operate
the seals and to lubricate them.
∑ The system is comprised of the gland seal assemblieswith their associated oil unit
located on the floor beneath the
generator, as shown inFig. 1.3-17.
Fig. 1.3-17 Seal Oil System and Gland Seals
86

EXCITATION SYSTEMS
EXCITER
The device that produces and supplies

Direct Current to the rotor excitation
windings is called Exciter. A Direct
Current is needed to make the Generator
an electromagnet. This Direct Current is
supplied by the excitation system. In fact,
like the main generator, the exciter also is a
generator, which supplies Direct Current
to the main Generator'srotor field windings,
as shown Fig. 1.3-18. Fig. 1.3-18 Excitation System
∑ The excitationsystem also regulatesthe output of the main Generator bycontrolling the
amount of Direct Current supplied to the field windings.
∑ The Generator excitation sy

stem is composed of the main Alternating Current Generator
exciter and voltageregulator,which automaticallyadjuststhe exciter's DirectCurrentoutput
and finallythe manuallyoperatedcontrolsand switches,which allowthe operatorto control
the exciter's output.
∑ The mainGeneratorconsistsof a rotatingelectro-magnet calledthe rotorwithina stationary

armature(stator). As the rotorfield flux cuts across the windings in the stator, a voltage is
induced in the armature windings.
∑ The rotor is made into an electromagnetby Direct Current flowing through the field
windings. The strength of the rotor'
s flux field depends on the amount of Direct Current in
the field windings. This in turn regulates the level of electrical output from the main
Generator.
∑ The Direct Current is

generatedin the exciter,by convertingsome of the mechanicalenergy
of the rotating turbine generator shaft assembly into electricalenergy. The mechanical
energy comes from the turbine units and it reaches the exciterway
by of the couplings that
connect the turbine shaft, the Generator shaftd an
the exciter shaft.
87

TYPES OF EXCITATION SYSTEMS
Excitation systems generally are divided into two categories:

∑ Brush and Slip Ring Exciters
∑ Brushless Exciters
BRUSH AND SLIP RING EXCITATION

The brush and slip ring exciter arrangement generates electricity in a rotating armature
within a stationary magnetic flux field.The electricity is collected from the exciter rotor
by slip rings and brushes and then supplied to the main Generator's rotor. Voltage
regulation in this type of excitation system is achieved by controlling the Direct
Current to the exciter's field windings, as shown Fig. 1.3-19.
Fig. 1.3-19 Brush and Slip Ring Excitation
BRUSHLESS EXCITATION SYSTEM

The brushless excitation system is shown in Fig. 1.3-20. This method of excitation
avoids the inherent inefficiencies of slip rings and brushes and was developed and
introduced by Westinghouse over twenty years ago. The brushless excitation system
consists of an Alternating Current Generator with a rotating armature and a stationary
magnetic field. The Alternating Current electricity generated in the rotating armature is
88

converted to Direct Current electricity by a rectifier, which is mounted on the same

shaft as the armature.
Fig. 1.3-20 Brushless excitation system

The exciter armature, the rect ifier and the main Generator's field windings all being on
the same rotating shaft, allows for a direct connection between the exciter'
s output leads and
the field windings on the main Generator.
The brushless exciter assembly also includes a
pilot exciter that supplies the current for the stationary field
windingsaround the exciter, as
shown in Fig. 1.3-21.
Fig. 1.3-21 Brushless Excitation System with Permanent Magnet Generator
89

The pilot exciter is an Alternating Current Generator that consists of a per

manent magnet
rotating field located at the end of the exciter rotor and a stationary armature. The
pilot exciter is usually referred to as the Permanent Magnet Generator (PMG). Before it
reaches the field windings on the main exciter, the output from the PMG is rectified
and controlled by the voltage regulator.
Brushless Exciter Components

The basic functional components of the brushless exciter are the permanent magnet
Generator (PMG), Voltage Regulator, Alternating Current Exciter Generator and the
rotating rectifier.
One of the principle advantages of this system is that many of the major components
(main exciter armature windings and rectifier wheel) are mounted on the same exciter
rotor shaft, as shown inFig. 1.3-22.
Fig. 1.3-22 Exciter rotor shaft
90

This entire rotating assembly is supported at two locations on a journal areabetween the
circulating blower and the armature windings and by the couplingwhere it attaches to the
Generator rotor.
The Permanent Magnet Generator (PMG) consists of a series of permanent magnets

attached to the inside bore of an extension of the exciter shaft. The stationary armature is
positioned inside this bore. The stator is wound withthree phases to produce three phase
Alternating Current electricity whenever the magnets rotate. This Alternating Current
electricity flows from the PMG statorto the voltage regulator.
The voltage regulator performs two functions. First it electronically rectifies the
Alternating Current to Direct Current and secondly, it controls the amount of Direct
Current delivered to the exciter's stationary field. From the armature coils, Alternating
Current flows to the rectifier wheel on the exciter rotor , as shown Fig. 1.3-23.
Fig. 1.3-23 Diode Rectifier and PMG
The rectifier wheel changes the Alternating Current electricity to Direct Current
electricity. This actually happens in an arrangement of diode assemblies that are installed
inside the wheel. Thus the arrangement of diode assemblies in the rectifier wheel
maintains a Direct Current that flows from the axial leads in the exciter's rotor shaft through
the coupling connection to the axial leads into the main Generator'
s rotor shaft, as shown in
Fig. 1.3-24.
91

Fig. 1.3-24 Current Flow to Main Generator
Brushless Exciter Features
As shown in Fig. 1.3-25, the featuresare as follow:
1. Permanent magnet pilot exciter provides power to the voltage regulator, which
controls the stationary field of the AC exciter.
2. The output from the rotating armature of the AC exciter is fed along the shaft to
silicon diodes mounted in the wheel on the shaft.
3. The wheel serves as the mounting for both the diodes and fuse.
the The output of the
AC exciter is rectified by the silicon diodes, the resultant Direct Current being
carried along the shaft to the rotating field to th
e AC Generator.
4. The rotating components are solidly connected together with no external leads
between the exciter and the Generator field.
92

EQUIVALENT CIRCUIT OF SYNCHRONOUS GENERATOR
Fig. 1.3-25 Equivalent Circuit of Brushless Excitation System
PARALLEL OPERATION OF GENERATORS
In power stations,several generatorsare generallyused to feed the energy supply network.

Generation can be adapted todemand by running onlythe number of generatorsrequired at
any given time. If more energy is needed, an addit
ional Generator inParallel is run, as shown
in Fig. 1.3-26.
A Generator can be brought on line only if:
∑ Its terminal voltage is identical to the network voltage.

∑ Its Generator frequency
is equal to the network frequency.
∑ The phase sequences of Generatornda network is the same.
∑ The phase relation of Generator and network is the same.
93

Fig. 1.3-26 Parallel Operation of Generators
The terminal voltage of the Generator is measured with a voltmeter and adjusted by varying
the excitation current until it is entical
id with the network voltage. The frequency is adjusted
by altering the speed of rotation of the Generator. A double frequencymeter {Synchro -
scope), as shown inFig. 1.3-27, with separate instruments for network and Generator can be
used to compare the frequencies.The phase sequence is checked with the aid of a phase -
sequence indicator. The sequence can be alteredchanging
by terminal connections.
Fig. 1.3-27 Synchroscope
After the Generatorhas been connectedin parallel,the loads are distributed. The excitation
current of the Generator and the power output of the prime mover are adjusted. If the power
input to the synchronousGeneratoris increasedafter it has been brought on line, it delivers
active power to the energy supply network. The rotor
then leads the rotating field set up in the
stator under load bythe load angle, which increases with the rise in non
-reactive load output
.
94

The active power delivered by the synchronous Generator is controlled by altering the
driving power input to the Ge
nerator. A change in the excitation current results in a change in
the reactiveload output. If the excitationcurrent is increasedafter the Generatorhas been
brought on line, the Generator contributesinductive reactive power to the energy supply
network. If the excitation current is reduced, it withdraws inductive reactive power from the
network. The amount and type of reactivepower deliveredby a synchronousGeneratoris
governed bythe excitation current
. To prevent the rotor speed fluctuating sharpl
y in response
to sudden changes in load, synchronous generators often have a damping winding
constructed like the squirrel cage winding in a squirrel
cage motor.
PREVENTIVE MAINTENANCE
Preventivemaintenanceaims to increasethe reliabilityand extend the lifetime ofgenerators
by providingappropriateservicingat the right time. It consists of annual system inspections
and component replacementsbased on a Generator-specific maintenance schedule. The
formation of defects in large synchronous machinesnormally
is a long process, so systematic
preventive maintenance can prevent unplanned shutdowns.
BENEFITS
∑ Increased Generator reliability
∑ Optimized maintenance costs and minimized repair costs
∑ Easy-to-plan maintenance budget
∑ Extended Generator lifetime
∑ PM kits based on extensive experience of requirements
COMPREHENSIVE MAINTENANCE
Preventivemaintenance includes the labor and parts needed to perform on -site work as
specified bythe maintenance schedule, as follows:
95

∑ Visual inspection of the Generator and its operating environmentInspection of the

connections.
∑ Checking the Generator mounting bolts and alignment.
∑ Inspection, testing and cleaning the stator and rotor.
∑ Inspection of the bearings and lubrication.
∑ Inspection of the exciter and rectifier bridge.
∑ Cleaning of the cooling system.
∑ Inspection and/or testing of the transformers and accessories

.
∑ Inspection of the Generator spare parts inventory

.
Once the maintenancework has been completed and the inspectiondata fully analyzed,a
detailedservicereport is provided. This includes recommendations for service actions (such
as “excitationsystem requires upgrading”),and for spare parts and special tools for future
actions. On-site training can be undertaken with maintenance work
.
PREPARATIONS FOR PREVENTIVE MAINTENANCE
The effectivenessof the preventive maintenance work depends on the quality of the
information provided by
the system manufacturer.
IN SERVICE REPORTS
Preventive maintenance is more effective when the information provided is as

comprehensiveas possible. If the information availableinsufficient,
is it is recommended that
a site surveybe performed on the Generator before the preventive maintenance
can be carried
out. Preventivemaintenancemust be planned well in advance in order to ensure th at the
required resources and service parts are available.
96

MAINTENANCE SCHEDULE
Experienceindicatesthat generators become more likely to fail after a number of years in
operation.In the case of synchronous generatorsthis typicallyoccurs after 5-10 years. The
main reason is ageing of the components,but operatingconditionsalso play a major role.
Failure of a component may result in damage to other parts of the machine, includingthe
stator and rotor. The maintenance schedules, as shownTable
in 1.3-1 are based on extensive
know-how providing an effectiveand systematicmeans of maintaininga specific type of
Generator.The maintenanceintervalsare planned accordingto those of the diesel engine to
avoid unnecessary shutdown time. The maintenance sch edules comply with any
specificationsissued by the component suppliers.Environmentaland operatingconditions
are also taken into account. Tough conditions, such as high ambient temperatures,high
vibrationlevels, humidity, dirt, or heavy loads can sign ificantlyshorten component lifetime
and more frequent maintenanceand component replacementintervals.In order to ensure
optimum performanceover the entire lifetime of a generator, it is recommended that
annual inspections are carried out in addition t o regular maintenance.
RECOMMENDATIONS FOR PREVENTIVE MAINTENANCE OF

GENERATORS
Refer to the Legend for maintenance activities , as follows in Table 1.3-1:
Table 1.3-1 Maintenance Schedule

Inspection (I) Replacement or Reconditioning (R) Performance of On-Site Work (P) Cleaning (C)
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98

TASK 1.3-1
OPERATE TWO 3 PHASE AC GENERATOR BY POWER

SYSTEM SIMULATOR (BUILDING 4 - ROOM NO. 409) AND
CONNECT THEM IN PARALLEL
OBJECTIVES
1. Write the steps required to operate two 3 phase AC generators in parallel and study
the loading effect on system frequency.
Two 3 phase – AC generator (Generator #1 and Generator #3 located in the power

system simulator (Building #4 - room # 409)
PROCEDURE
The instructor will demonstrate safe parallel operation of two 3f generators.

1. Start both generators #1 and #3 in the Power System Simulator.
2. Operate the synchronizing device and assure that:
∑ Generation voltages are equ al.
∑ Generation frequencies are equal.
∑ Synchroscope pointer rotates slowly or constantly stands still.
If the difference is big and the synchronization device indication rotates at fast
speed press the excitation winding control switch for motor to upper si de to control
its speed (control frequency value) and at the same time press the excitation to
raise the voltage reading until it reach 600 Volts and the frequency reading 60 Hz
so that the output voltages for the two generators are equal.
99

3. Connect the Bus-Tie switch when the synchroscop e pointer is at or very close
to12 o'clock position.
4. Connect some different loads to feed them via generator no.1 and generator
no.3. Supervise the frequency and voltage readings for the two generators.
Readjust the voltage and frequency reading to reach 600 volt and 60 Hertz
again, if needed.
5. Disconnect the loads . Then stop and disconnect the two generators safely.
V V V A
1 -RUN / START Control Switch
F A V A 2 -DC Motor -3 / 125 V Supply Switch 's
10
3 -Gen -3 Excitation Isolator Switch
KW V A 4 -DC Motor -3 Raise / Lower Excitation
Control Switch
5 -Gen -3 Raise / Lower Excitation
Control Switch
6 -Gen -3 Excitation SupplySwitch (250 V)

7 -Gen -3 Output Breaker
8 -Gen -3 Output Disconnect Switch .
Rec.
9 -Generator Isolation Disconnect Switch .
10 -Frequency Meter Selector Switch .
51
7 8
6
51
5 4
9
51
1
3 2 G-3
32
Fig. 1.3-1-1 3 Phase AC Generator Operation
100

UNIT-2
MOTORS AND POWER

TRANSFORMERS
101

102

UNIT-2
MOTORS AND POWER TRANSFORMERS
UNIT OVERVIEW
DESCRIPTION
Unit 2 consists of three lessons as follows:

Lesson 2.1 Types of Motors, Protection and Control concluding with Preventive
Maintenance.
Lesson 2.2 Transformer Components, Operating Voltag es and Cooling System
Lesson 2.3 Transformer Tests.
OBJECTIVES
Upon completion of this unit , the participants should be able to :

∑ Describe the operation of different t ypes of Motors (AC & DC):
Squirrel Cage, Capacitor Start, Shaded-Pole Motor, Wound Rotor , 1-Phase and
3-Phase Motor, Dual Voltage Motor, Parallel Star Connected Motor, Parallel
Delta Connected Motor, Synchronous three phase motor
∑ Understand Protection and Control Elements in Motors:
Circuit Elements, Thermal/Magnetic Circuit Breaker, Overload Relays and
Starters (Contactors), Simple Control Circuits and Magnetic Controllers
∑ Perform and supervise Preventive Maintenance of Motors.
∑ Familiarize with Transformer Components:
∑ Familiarize with SEC Operating Voltages, 380 kV/115 kV/69 kV.
∑ Familiarize with Cooling Methods:
∑ Familiarize with Transformer Test Methods.
103

104

LESSON 2.1
TYPES OF MOTORS, PROTECTION

AND CONTROL
105

106

LESSON 2.1
TYPES OF MOTORS, PROTECTION AND CONTROL
LESSON OVERVIEW
DESCRIPTION
This lesson discusses Types of Motors, Protection and Control and concludes with
Preventive Maintenance.
OBJECTIVES
Upon completion of this lesson the participants should be able to :

∑ Describe the operation of different types of Motors (AC & DC)
Squirrel Cage, Capacitor Start, Shaded -Pole Motor , Wound Rotor , 1-Phase and 3-
Phase Motor, Dual Voltage Motor, Parallel Star Connected Motor, Parallel Delta
Connected Motor, Synchronous three phase motor
∑ Understand Protection and Control Elements in Motors:
Circuit Elements, Thermal/Magnetic Circuit Brea ker, Overload Relays and Starters
(Contactors), Simple Control Circuits and Magnetic Controllers
∑ Perform and supervise Preventive Maintenance of Motors.
Task 2.1-1: Demonstrate Motor Control Circuits.
107

108

DC MOTORS
Motors (AC & DC) are as important component s in a Power System as in industry . A
power plant of generating capacity of 1600 MW utilizes an approximate total of
10,000 motors for reliable operation of the plant; AC & DC motors, drive pumps,
fans, control valves etc. In all power plants, there are many auxiliary types of
equipment such as pumps, compressors and fans. These auxiliaries are driven by
electric motors (AC/DC). The auxiliaries driven by the DC motors are generally used
for standby functions. There are many motors at the plant that get thei r power from a
DC source such as, Emergency oil pump, seal oil pump, turning gear motor and so on.
DC MOTOR PRINCIPLE OF OPERATION
In DC motors, coils carrying current

(Armature) are placed in a magnetic
field, as shown in Fig. 2.1-1. The torque
is produced by the interaction of the
armature field and the magnetic field.
Power is supplied to the stationary field
winding through direct connection and
through a commutator to the armature.
Fig. 2.1-1 DC Motor Principle
The commutator permits the current to
flow in only one direction to the
armature winding.
TYPES OF DC MOTORS
There are three basic types of DC motors
, as shown in Fig. 2.1-2.
109

∑ Series wound type
∑ Shunt wound type
∑ Compound wound type
Fig. 2.1-2 Types of DC Motors
All of these motors are identical in construction, but they are different inthe methods of
connection and the way field current and armature currents are changed, either by
change in mechanical load (Torque) or by controller external to the motor.
SERIES MOTORS
A series motor has its field winding connected in

series with the armature,as shown in Fig. 2.1-3(a).
Its only source of magnetism is the armature

current. Since the armature current depends on the
load, the flux will be very low at small loads,
causing this type of motor to have a very high no load
speed. This can be a hazard for large motors if the
Fig. 2.1-3(a) Series Motor
speed becomes excessive.
OPERATING CHARACTERI
STICS
As shown in Fig. 2.1-3(b), we can deduce series motor
load characteristics as follow:
∑ Series motorshave high starting torque.
∑ Series motor speed is load dependent.
∑ Series motor may race under no load conditions.
∑ Series motor speed can be controlledby varyingthe Fig. 2.1-3(b) Series Motor
armaturevoltage or field current. Load characteristics
110

APPLICATIONS
∑ Electric Vehicles ∑ Lifting Gear ∑ Vehicle Starters
SHUNT MOTOR
By designing a field winding with many turns, a small current can set up a strong
magnetic field. Therefore, the resistance of the field windings is relatively high and is
connected directly across the line voltage for which motor is designed. Field windings
are only necessary to produce flux in an electromagnetic circuit. The windings would not
be necessary if the poles are made of permanent magnetic materials. Such materials
would not b e practical since the flux could not be changed and one of the advantages of
DC motor speed control would be lost.
The armature windings must carry large currents to

produce the necessary current to create the required
field and, therefore, must be designed with low
resistance. In large motors this may be less than
0.25W. The shunt motor is a DC motor whose field
is shunted across its armature, with both connected
to the DC line, as shown inFig. 2.1-4.
Fig. 2.1-4 Shunt Motor
OPERATING CHARACTERISTICS
As shown inFig. 2.1-4(b), we can deduce shunt motor

characteristics as follow:
∑ Slight change in speed following change in load
∑ Speed control via armature voltage or field current
APPLICATIONS
∑ Machine Tools ∑ Conveyor Sy

stems
111

COMPOUND MOTOR
The compound motor combines the characteristics of

the shunt and series motor, having one series and one
shunt winding, as shown in
Fig. 2.1-5.
OPERATING CHARACTERI
STICS
As shown in Fig. 2.1-5, we can deduce shunt motor

characteristics as follows:
∑ Predominantly
, series or shunt characteristic Fig. 2.1-5 Compound Motor
depending on compounding
∑ Counter compounding may produce instability
APPLICATIONS
∑ Machine tools ∑ Rolling mill drives
∑ Driving fly
wheel masses (Presses, stamping plants, shearing plants)
DC MOTOR STARTING
The difficulty with this arrangement is in starting the motor. The low armature resistance
causes a very high starting current if the armature winding is directly across the line.
The starting current must be limited by connecting a starter resistance. After the motor
has accelerated to its rated speed, counter emf (cemf)
oppose starting current and reduce to
acceptable limit.
Any break in the field circuit will cause the cemf to go nearly to zero,
resultingin the same
inrush of current as if the starter resistance were not used when starting. This is a very
dangerous situation that will cause the motor speed to increase beyond safe limits. The no
field release will cause the handle to fall back
to the off position.
112

Armature current increases as torque

increases and the speed of the shunt motor
changes only about 5% throughout the
range of the load from no load to full load.
For this reason the shunt motor can be
described as virtuallya constant speedmotor
through theentire rangeof the load. Fig. 2.1-
Fig. 2.1-6 Shunt Motor Automatic Starter
6 shows shunt motor automatic starter.
REVERSE DIRECTION OF DC MOTOR
Direct current motors are easily reversed. By reversing either the armature or the field
connections changes the direction of flux set up by the poles with respect to the
armature. The North Pole will besouth and vice versa with respect to the armature.
This will cause the conductor to move to

the right. If the armature current is
reversed instead of the field current, the
same will be true. The conductor will
move to the right and the lines of flux
around the conductor will be
counterclockwise. Fig. 2.1-7 shows the Fig. 2.1-7 Reverse Directionof DC Motor
connections for reverse direction.
DC MOTOR SPEED CONTROL
The wide ranges of possible speed variations permit extensiveuses of DC motors. If rated
voltage is applied to the field and armature circuits, the motor will operate at rated
nameplate speed. If the armature voltage is reduced, but the flux is maintained with
rated voltage on the field, the speed will be reduced in proportion to the reduced
voltage.
113

Several methods of obtaining this variable DC

voltage supply are possible. Resistance unit
(Rheostat) is one possibility, as shown inFig. 2.1-8.
Much power is wasted and a different value of
resistance is needed for each desired speed. Also,
speed regulation is poor as load changes. Fig. 2.1-8 Speed Control of DC
Shunt Motor
An excellent control method for medium size and smallerDC motors is the use of Silicon
Controlled Rectifiers (SCR). These solid state devices can convert AC to DC very
efficiently and at the same time control the DC voltage. SCRs are available for currents
of hundreds of amperes and can be used to control medium size DC motors by armature
voltage control from rated speed to zero. To increase the speed of the DC motor above
rated speed is quite simple as reduction of flux increases speed.
AC MOTORS
Fig. 2.1-9(a) shows some of important AC motor types.
Fig. 2.1-9(a) Types of AC Motors
INDUCTION MOTORS
Asynchronousor induction motors are the most commonly used electricalpower unit on
account of their simplicityand cheapness of constructionand their reliabilityof operation.
Accordingto the type of rotor employed,they are classifiedas squirrelcage motors or slip
ring motors, as shown inFig. 2.1-9(b).
114

Fig. 2.1-9(b) Induction Motors
SQUIRREL CAGE INDUCTION MOTOR
The squirrel cage induction motor is by far the most commonly used type of AC
motor. It
is economical to build ha ving good operating characteristics and r equires virtually no
maintenance. Small fractional horsepower sizes usually are woundfor single phase, but
over 1 HP, three-phase operation is more practical for higher Horse Power. The three-
phase windings produce more uniform torque. Single -phase motors are used mostly in
residences where a three-phase power supply is usually not available or necessary.
THREE PHASE SQUIRREL CAGE INDUCTION MOTOR
Construction
The three-phase squirrel cage induction motor has two circuits, a stator and a rotor. The
stator consists of three (phase) windings placed symmetrically in a slotted, laminated sheet
steel magnetic circuit.Fig. 2.1-10 illustrates the parts of a three-phase induction motor.
115

Fig. 2.1-10 Squirrel Cage Induction Motor
These three (phase) windings must be

identical as to turns and size and may be
connected to the three-phase source in
either delta or wye, as shown in Fig.
2.1-11.
Fig. 2.1-11 Three Phase Induction Motor

Connections
Squirrel Cage Induction Motor Characteristics

The squirrel cage rotoris built with a very small air gap and is equipped withclose-fitting
ball bearings rather than sleeve bearings that
must have clearance,as the rotor bars are cut
by the stator flux they have a voltage induced by transformer action. A current will flow
in the short-circuited rotor bars as, shown in
Fig. 2.1-12 causing a magnetic flex around the
bars. This develops a torque causing the rotor tofollow the rotating field.
116

The starting current will be high, but of short duration and decreases as the rotor
approaches the speed of the rotating field. The rotor cannot reach the synchronous speed.
If it could, no flux would cut the rotor and there would be no induction or rotor current or
torque and the motor would slow down.
Fig. 2.1-12 Squirrel Cage Rotor
The actual rotor speed slips behind the rotating field sufficiently so it can induce enough
current to produce the torque needed to satisfy the demands of the mechanical load.This
inability to keep up with the synchronous speed is an important measure of an ni duction
motor's performance and is called Slip. It may be measured in revolutions per minute. It
also is expressed in percent of synchronous speed. When written as a decimal
, its symbol
is "S"or Percent slipS %.
NSYN - N rotor
s% = ¥100
NSYN
As mechanical load is increased, the motor slows down slightly. This increases the slip,
induces more current in the rotor secondary and by transformer action an increase in
current and power is drawn by the stator from the power supply.
An induction motor with
no load draws only a magnetizing current. The power input is small, only to provide for
rotational losses. This causes the motor to operate with a very
117

low Power Factor (PF). At half load, the PF

is still quite low (PFª 0.5) and this is one of
the principal reasons for low PF loads in
industry. Induction motor speed changes
from no load to full load with a small
percentage (10%). This is good speed
regulation and the induction motor may be
called "constant speed motor", as shown in Fig. 2.1-13 Load Curves of Three Phase
Fig. 2.1-13 curve. Induction Motor
Operation of Squirrel Cage Induction Motor

The three-phase supply connected to the
stator of an induction motor may change
in magnitude and direction. Therefore,
the induced magnetic field may also
change accordingly. Fig. 2.1-14 shows a
three-phase supply sine wave connected
to the stator winding of a motor. The
three-phase have a phase difference of
120∞ between each two phases, as shown
in Fig. 2.1-14. The revolving magnetic
field has the same effect on the squirrel
cage rotor as that produced by a magnet
moving around the rotor, as shown in
Fig. 2.1-14 Operation of Squirrel Cage
Fig. 2.1-15. Induction Motor
118

The rotating magnetic field set up by the three-

phase current in the stator passes through the
many conductors formed by the bars in the
squirrel cage rotor. This action is shown in
where the moving magnets represent rotating
poles. Fig. 2.1-15 Squirrel Cage Rotor
As this rotating magnetic field is increasing in one direction, then decreasing and then
increasing in the other direction, a current is induced in the squirrel cagerotor bars.There
are two magnetic fieldsinduced in the squirrel cage induction motor
:
1- Magnetic fieldin the stator

2- Magnetic field caused by
the currents induced in the squirre
l cagebars
Therefore, a mechanical force is produced on the rotor bars (Right Hand Rule). This
force causes the rotor to get a torque in the direction of rotation of the stator magnetic
field. The rotor always rotates in the same direction as the rotating field of the stator. The
rotating magnetic field of the stator rotates once during every complete cycle of alternating
current. The speed of the rotating magnetic field of the stator is called the Synchronous
Speed of induction motor.If the supply frequency is 60Hz; the magnetic field rotates at:
rpm = 60Hz × 60 sec. = 3600 rpm.
WOUND ROTOR INDUCTION MOTOR

Another type of three-phase motor is the wound rotor or slip ring, as shown in Fig. 2.1-
16(a), where the rotor is an insulated, three-phase, wye-connected winding. Three slip rings
permit the endsof this winding to be connected to anexternalcircuit.
1. Shaft 6. Frame
2. Stator winding 7. Brush holder
3. Rotor winding 8. End plate
4. Laminated rotor core 9. Slip-rings
5. Laminated stator core 10. Terminal box

Fig. 2.1-16(a) Slip Ring Induction Motor
119

The rotor windings can be wound for2, 4 or more

pair of poles per phase. The construction of the
wound rotor induction motor stator is almost the
same asfor the squirrel cage motor.But the rotor is
different and has 3 slip rings andbrush holders for
external connection, as shown in
Fig. 2.1-16(b). Fig. 2.1-16(b) Slip Ring Motor
WOUND ROTOR MOTOR CHARACTERISTICS
The wound rotor motor has an insulated winding with the same pole configuration as
the stator. By means of three slip rings on the rotor shaft, the windings can be connected
to three wye-connected external resistors, to reduce starting currents. As the motor
accelerates, the resistances may be removed andthe rotor shorted at the brushes. When
short-circuited, the rotor performs the same as the squirrelcage rotor. The same resistors,
if rated for continuous duty, may be used as a variable speed control. Resistance in the
rotor circuit will increase slip for a particular value of the torque. This results in
decreasing speed. Fig. 2.1-16(c) shows a wiring diagram of a wound rotor motor
connected to its controlling resistors.
Fig. 2.1-16(c) Load curves of wound Rotor Motor
Wound rotor motors are used where very high starting torques are necessary such as
for compressors or where control speed is required below synchronous speed. Because
of I2R losses in resistors, the efficiency is decreased as compared to an ordinary
polyphase induction motor.
120

SYNCHRONOUS MOTORS
Synchronous motors are built from the smallest clock motors to t hose of thousands of
horsepower. Large motors, as shown in Fig. 2.1-17(a), can be adjusted to draw a
leading current, thereby correcting the PF of a load with low lagging PF, perhaps
because of under-loaded induction motors.
A large synchronous motor drivi ng a fixed load such

as ventilation or a refrigeration system can improve
the Power Factor of the entire plant substantially
with the proper field current adjustment. If desired, it
can be operated with no mechanical load on its shaft,
when adjusted to draw a leading current and it is
called a synchronous condenser when operated this
Fig. 2.1-17(a) Synchronous
way. Its electrical characteristics are now the same as
Motor
those of a capacitor, except of course it is a dynamic
and not a static device.
PRINCIPLEOF OPERATION
When the stator winding of a three phase synchronous machine is connected to a three
phase network, a rotating field is set up in the machine. As shown in Fig. 2.1-17(b), if
the rotor is started in the direction of rotation of the rotati ng field, the north pole of the
rotating field draws the south pole of the rotor with

it and the south pole of the rotating field draws the
north pole of the rotor. The rotor continues to turn
at a speed of rotation, which can be calculated from
the formula "n = f/p". It turns synchronously with
the rotating field. The machine is now working as a
motor. The experimental set-up, which we used to
determine the direction of rotation of the rotating Fig. 2.1-17(b) Rotor of
SynchronousMotor
field, is actually a model of a synchronous motor.
121

OPERATING CHARACTERISTICS
If three-phase current is fed to the stator winding of a three-phase synchronous

machine and its rotor is started by a pony (starting) motor, the rotor continues to turn
at the same speed as the rotating field. Small synchronous motors have damping
windings. These cause the motor to start asynchronously. While the motor is being
run up, the damping winding acts in the same way as the squirrel cage winding in a
squirrel-cage motor. Once a high enough speed has reached, the motor transfers to
synchronous mode of running. The machine can be started in the same way by
bridging the excitation winding, which then functions as a short-circuited winding.
Once a constant speed has been reached, the bridge is removed and excitation current
switched on, the motor then transfers to synchronous running mode. The speed of
rotation of a synchronous motor does not change under load. As the load increases the
rotor lags behind the rotating field by an increasing load angle and as a result, it pulls
out of synchronism until speed drops to

zero. Fig. 2.1-17(c) shows the load
curve of synchronous motor
Fig. 2.1-17(c) Load Curve of Synchronous Mot

or
APPLICATIONS
1- Piston compressors 3- Machine drive with hig h speed stability

2- Converter sets 4- Phase shifter for PF correction
DUAL VOLTAGE MOTORS

Electric motors manufacturers sometime build motors that can run on two voltages.
These are called dual voltage motors. There are four types
:
∑ Starconnected motors. ∑ Delta connected motors.

∑ Parallel star connec
ted motors. ∑ Parallel delta connectedmotors.
122

STAR CONNECTED MOTORS
Fig. 2.1-18 shows that each phase consists of two windings . If connected across 460V,
the phase voltage will be (460/ 3 ) and the voltage across the individual phase
winding will be 133V (266/2). This connection is used for high voltage .
Fig. 2.1-18 Star connected Motors
PARALLEL STAR CONNECTED MOTOR
Fig. 2.1-19 shows a parallel star connected motor. In this example, the full supply voltage
is connected across each winding. The parallel star connection consists of two single
windings per phase star connections, connected in parallel.This connection is used for low
voltage.
Fig. 2.1-19 Parallel Star connected Motor
123

DELTA CONNECTED MOTORS
Fig. 2.1-20 shows that each phase consisting of two windings per phase connectedin series.
Therefore, connected to 460V, the voltage across each winding is 230V, (460/2). This
connection is used for high voltage
Fig. 2.1-20 Delta connected Motors
PARALLEL DELTA CONNECTED MOTORS
Fig. 2.1-21 shows a parallel delta connected motor consisting of twosingle windings per
phase delta connections, connected in parallel. Therefore, the voltage across each phase
and therefore, each winding is230V.
Fig. 2.1-21 Parallel DeltaconnectedMotors
124

SQUIRREL CAGE MOTOR SPEED CONTROL

Synchronous speed, Ns = 1 2 0 F Where f = frequency & p = number of poles
P
As seen before, the rotor can never attain the synchronous speed or there will be no
cutting of the magnetic lines. The ratio between the difference of synchronous and rotor
speeds is called the slip NS.and gives the following relationship:
NS - Nr 120 F
N= = NS (1- S) = (1- S)
N P
To change the speed of the induction motor, you either change the frequency or the
number of poles. As the frequency is fixed by the generation, the only way to change
speed is to changethe number of poles by the followingtwo methods:
1. To have completely separate winding sets of poles. For example, two, four, six or
eight. All the necessaryleads are brought outof the stator to a drumcontroller through
which the necessarychangein connecti
on is made.
2. Consequent Pole Method is the most popular method.

It is a squirrel cage motor that
has either one or two stator windings. Eachwinding has w
t o sets of connections and
can produce two different numbers
of magnet poles. The speed of the motor can be
changed by changing theconnections to the windings.
Fig. 2.1-22 below shows the coils carrying current for one phase of a three
phase four pole
motor winding. Fig. 2.1-22A shows the connection for high speed and Fig. 2.1-22B shows
the connection for low speed operation. The consequent pole means that if there are any
two similar poles beside each other consequently there should be a different pole between
them.
Fig. 2.1-22 Squirrel Cage Motor Speed Control
125

SINGLE PHASE MOTORS

Most fractional horsepower motors are used where only single-phase power is available. In
industry, AC motors of less than one-half horsepower are single-phase. It is used in many
industrial applications, such as operating fans, pumps,
time clocks and power tools.
STARTING CONCEPTS
All single-phase motors have one primary problem. That is, how to make them self-
starting. A 2-pole stator winding and rotor, only remains stationary and hums without
turning. If two identical windings are connected in parallel to a single-phase source, the
magnetic field produced willalternate but not revolve. Thetwo windings are equivalent to
one winding, as shown in Fig. 2.1-23.
Therefore, so as to make the field revolve

you have to make the currents in the two
windings differ in time phase. These
currents can be made to differ by as much
as 90∞ in order to produce a rotating
magnetic field. Fig. 2.1-23 Starting Concepts
Fig. 2.1-24 shows connections for splitting one phase, i.e., by establishing two
magnetic fields, which are 90∞ out of phase. This is necessary for the starting instant,
after starting and the rotor reaches 75% of its normal speed, a centrifugal switch opens
and disconnects theauxiliary poles winding.
Fig. 2.1-24 Split Phase Motor
126

CAPACITORSTARTMOTOR
The capacitor start motor is a single

-phase motor made
in size ranging from /8
l HP to 7.5 HP. It is used where
high starting torque is required such as refrigerators,
Air compressors and power tools, as shown in Fig.
2.1-25. It has a running and a starting winding. The
capacitor is connected in series with the starting
winding to achieve the phaseshift and higher starting
torque. A larger angle between the two currents will Fig. 2.1-25 Capacitor Start Motor
increase the displacement of the stator poles.
TYPES OF CAPACITOR START MOTORS

Capacitor StartMotors
As shown in Fig. 2.1-26, it has a capacitor
in the starting winding, which is
disconnected by a centrifugal switch at about
70% of the rated speed.
Fig. 2.1-26 Capacitor Start Motor
Permanent Split Capacitor Motor

It operates with starting winding and capacitor continuously in the circuit. It has no switch to
disconnect the starting winding from the circuit.
Two Capacitor Motor

It uses two capacitors; onewith large valuefor
the starting and the other with a smaller value
remains in the circuit while the motor is
running, as shown in Fig.2.1-27.
Fig. 2.1-27 Capacitor Start-Run Motor
127

Capacitor
When using a capacitor with a motor, make sure whether it is a DC capacitor or AC

capacitor. Capacitors designed to operate on AC have no marking on theterminals. A DC
electrolyte capacitor in an AC circuit can blow up.
Centrifugal Switch
There are many mechanisms to achieve
centrifugal switch function. The basic idea
is that it closes a circuit when the shaft is
standstill and opens the circuit (starting
winding) when the shaft attains75% of its
normal speed. The following Fig. 2.1-28
shows two mechanisms of centrifugal
switch and its application in capacitor start
motor.
Fig. 2.1-28 Centrifugal Switch
Centrifugal Switch Operation

It is similar in connection and operation to the split -phase motor. The only differenceis
that the phase displacement is attained by adding a capacitor in series with the starting
winding, centrifugal switch is added to disconnectthe starting winding when the motor
speed is about70% of the ratedspeed. The capacitor motor can be reversed by reversing either
of the two windings
.
Shaded Pole Motor

The shaded pole motor has very little starting torque. The stator has salient poles rather
than distributed ones. One side of the pole has a slot cut. Around this part of the pole a
current is induced in a copper ring that sets up a small pole out of phase with the main
pole. This type of motor cannot easily be reversed. It is used in small sizes for driving
loads such as fans since only small starting torque is necessary.
Fig. 2.1-29 shows this pole
128

arrangement. The rotor is the typical squirrel cage. Therefore, speed is a function of line
frequency and the number ofstator Poles.
Fig. 2.1-29 Shaded Pole Motor
Universal Motor
A universal motor operates on DC as well on AC up to 60Hz. It develops more horse
power per pound than any other AC motor. This high ratio of power to weight is
accomplished by the high speed developed (Armature speeds of over 20,000 rpm). It is built
to suit the following applications:
Applications
∑ Portable hand drills ∑ Vacuum cleaners

∑ Power saws
Universal Motor Construction

The universal motor is
constructed in the same way
as the DC series motor. The
stator is built, as shown in Fig.
2.1-30. The armature is built
with commutator and brushes
for the universal motor in drill.
a
Fig. 2.1-30 Universal Motor
129

Theory of Operation
The idea is to operate a DC series motor on AC supply. The field of a DC series motor is
wound with fewer turns and larger wire than the DC shunt motor. Therefore, the
inductive effect is less and the magnetic field is approximatelythe same as when AC is
applied. Because the field and armature
are in series, the currents IA (Armature current) and
IF (Field current) are the same in both. There is no time lag between their magnetic fluxes
and the motor will operate satisfactorily.One of the most outstanding features of a
universal motor is that it has the highest horsepower-per-pound ratio of any AC motor
because of its abilityto operate at high speeds. A typical 1/2 HP, 1750 rpm induction
motor weighs about 30 pounds and has a 5/8 inch shaft. A 1/2 hp, 19.000 rpm universal
motor weighs2 1/2 pounds and has5/16 inch shaft. The advantages of universal motors over
induction motors are high starting torque, adjustable speed capabilities, small size and
economy.
SpeedControlof UniversalMotor
Speed control of a universal motor is quite simple because speed is sensitive to both voltage
and magnetic flux changes. A rheostat or adjustable transformer, as shown
Fig.in2.1-31, can
vary the speed from zero to maximum speed control of a small universal motor.
Fig. 2.1-31 Speed Control of Universal Motor
MOTORCONTROLS
MOTORCIRCUIT ELEMENTS
As shown inFig. 2.1-32, the elements from which motor circuit is built: are
∑ Motor disconnecting means ∑ Motor overcurrent protection
∑ Motor controller (Contactor) ∑ Motor branch circuit overcurrent
protection
130

Fig. 2.1-32 MotorCircuit Elements
NOTES
1. C and D are called motor starters.
2. A, B and C are called combination starters,
A and B maybe:
∑ Safety switches ∑ Motor circuit switches ∑ Circuit breakers
BRANCH CIRCUITS
The NEC defines a branch circuit as the portion of a wiring system extendingbeyond the
final overcurrent device protecting the circuit. All power wiring to a motor must be
protected. Means used for branch circuitprotection are Circuit Breakers and Fuses.
CIRCUIT BREAKERS
Under normal conditions current rating, a

circuit rating, overload or short circuit
current, the circuit breaker is an automatic
overcurrent device, as shown in Fig. 2.1-
33.
Fig. 2.1-33 Over-Current Circuit Breakers
131

Types of Ci rcui t Breakers

∑ Thermal circuit breaker
∑ Magnetic circuit breaker
∑ Thermal-magnetic circuit breaker
Thermal-Magnetic Circuit Breaker
A thermal-magnetic circuit breaker has

both a thermal strip and a magnetic
coil. The thermal strip provides a time
delay for momentary overloads. The
magnetic coil provides instantaneous
trip on high or short circuit currents.
The magnetic trip also protects the
bimetallic strip from extreme
overheating that can destroy it. Fig.
Fig. 2.1-34(a) Thermal-Magnetic Circuit Breaker
2.1-34(a) shows the thermal-magnetic
circuit breaker
OVERLOAD RELAYS (OL)

Most motor burnouts are caused by currents exceeding the motor current rating. In the
thermal OL relay, as shown in Fig. 2.1-34(b), excessive current is translated into a
temperature increase. The increased temperature actuates the relay, which trips a latch
opening the motor control circuit and disconnecting the motor from theline.
Fig. 2.1-34(b) Overload Relay
132

The heater element is connected in series with the motor circuit. Tripping is
accomplished by the relay, which opens the motor control circuit. Bimetallic OL opens
motor control circuit when the heat produced deflects the bimetallic strip as shown Fig.
in
2.1-35.
Fig. 2.1-35 Overload Condition
STARTERS (CONTACTORS)
Most motor applications require the use of remote control devices to start and stop the
motor. Magnetic contactors, as shown below are commonly used to provide this
function. Contactors are also used to control distribution of power in lighting and
heating circuits, as shown in Fig. 2.1-36.
Fig. 2.1-36 Contactors
133

Fig. 2.1-37 shows interior of a

basic contactor. There are two
circuits involved in the operation of
a contactor: the control circuit and
the power circuit.
The control circuit is connected to

the coil of an electromagnet and the
power circuit is connected to the
stationary contacts. Fig. 2.1-37 Interior of Basic Contactor
The operation of this electromagnet is similar to the operation of the electromagnet we

made by wrapping wire around a soft iron core. When power is applied to the coil
from the control circuit, a magnetic field is produced, magnetizing the electromagnet.
The magnetic field attracts the armature

to the magnet, which in turn closes the
contacts. With the contacts close, current
flows through the power circui t from the
line to the load . When current no longer
flows through the power circuit, the
electromagnet coil is de-energized, the
magnetic field collapses and the Fig. 2.1-38 Contactor Operation
movable contacts open under spring
pressure, as shown in Fig. 2.1-38.
134

CONTROL CIRCUITS AND MAGNETIC CONTROLLER
Fig. 2.1-39 shows 3-wire power

control circuit for a simple starting
arrangement of three-phase
squirrel cage induction motor. This
circuit is used to start a motor for
some industrial process. The
components in a 3-wire control
circuit are momentary pushbutton
(STOP), momentary pushbutton
(START), normally open relay
contact (M), relay coil (M) and the
thermal overload relay contact Fig. 2.1-39 Power Circuit
(OL), as shown in Fig. 2.1-40.
The sequence of operations here is a little more complex. When the start button is
pressed, the coil of magnetic motor starter M is energized and the motor starts,
provided the running overload current is within the values of the overload relay OL.
However, there is one very important difference. A normally open contact of magnetic
motor starter M seals around the start button to latch the circuit. To stop the motor, the
STOP button is pressed, which, in turn, opens the latching contact M de-energizing
the coil of magnetic motor starter M, and stopping the motor.
Fig. 2.1-40 Typical Control Circuit
135

See Fig. 2.1-41 for a list of common symbols used in ladder diagrams and motor
control circuits.
Fig. 2.1-41 Common Symbols used in Motor Control Circuits
PREVENTIVE MAINTENANCE
The aims of the preventive maintenance program are increased reliability, optimized
performance and extended lifetime. It recommends that electrical machines are
maintained throughout their lifetime in order to ensure maximum availability and to
eliminate unplanned repair costs.
Maintenance Schedule
The maintenance schedule provides an effective and systematic means of maintaining
a specific motor. Each product family has a unique maintenance schedule based on
manufacturer's recommended instruct ion manual. The maintenance schedules comply
with any specifications issued by the component suppliers and they also take
environmental and operational conditions into account.
Preventive Maintenance Kits

Preventive maintenance kits are a vital part of the preventive maintenance program.
The kits contain all the parts that need to be replaced during maintenance of a specific
motor.
136

Spare Part Packages

The availability of appropriate spare parts in preventive maintenance kit with relative
resources is very crucial in cases of failures and it is highly recommend ed that spare
part packages are stored on -site.
Optimum Return on Assets
Motors need regular maintenance and it is recommended that a systematic long term
preventive maintenance program is implemented in line with the regular maintenance
schedules. This ensures optimum performance over the motor’s entire lifetime and
provides the best possible return on motor assets.
Preventive Maintenance Recommendation for Synchronous Motors

(Variable Speed Synchronous Motors)
Maintenance activities to be carried out by factory approved engineers .
LEGEND: Inspection (I) Maintenance work (W) Cleaning (C)

Test/Measurement (T) Replacement or reconditioning (R)
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138

TASK2.1-1
DEMONSTRATE MOTOR CONTROL CIRCUITS
OBJECTIVES
∑ Identify parts of different types ofmotors.
∑ State the elements of motor control circuits

.
Motor control circuit equipment
Motor control trainer, Model AC-100FT
SAFETY PRECAUTIONS
1. Wear the required safety equipment.
2. Keep a safe distance from the energized equipment

.
3. Follow the trainer's directions .
PROCEDURE
1. Receive from your instructor, the following

:
∑ Two start-stop push button contr ollers.
∑ Three-phase 220V coil electromagnetic starter
∑ Three-phase overload relay.
∑ Fuse disconnect switch.
∑ Three-phase 220V AC induction motor.
∑ No. 14 and No. 10 AWG wires.
139

∑ Plywood board, wood screws.
∑ Electrician's tools:- Simpson meter, wire connectors,sulation

in tape.
2. Connect the control circuit, as shown in Fig. 2.1-1 below using wire size 14 AWG.
This is standard way of connecting Start/Stop push button.
3. Connect the other Stop/Start push button control, as shown. This will act as a remote
Stop/Startunit using no. 14 wire.
Fig. 2.1-1 Motor Control Circuits
140

LESSON 2.2
TRANSFORMER COMPONENTS,
OPERATING VOLTAGES AND
COOLING SYSTEM
141

142

LESSON 2.2
TRANSFORMER COMPONENTS, OPERATING
VOLTAGES AND COOLING SYSTEM
LESSON OVERVIEW
DESCRIPTION
In Lesson 2.2 discusses Transformer Components, Operating Voltages and Cooling

System.
OBJECTIVES

∑ Familiarize with Transformer Components:
Radiator, Cooling Fans, Manual/Automatic Control, Conservator, Nitrogen
Blanket, Pressure Relief Vent, Breathers, Bushings, Buchholz Relay.
∑ Familiarize with SEC Operating Voltages, 380 kV/115 kV/69 kV.
∑ Familiarize with Cooling Methods:
Natural air, forced air, Oil-immersed forced air Cooling.
143

144

THREE -PHASE POWER TRANSFORMER COMPONENTS

The high voltage transformer has the basic components, as shown in Fig. 2.2-1.
1-Flange for Nitrogen Sealing
2-Conservator
3-Sudden Pressure Relay
4-Oil-Inlet Valve
5-Relief Vent
6-Low Voltage Bushing
7-Suspension Lug
8-BCT Terminal
9-Tank
10-Tap Changer
11-Tap Changer Handle
12-Fastener for Core and Coil
13-Lifting Hook. for Core and
Coil
14-End Frame
15-Coil Pressure Bolt
16-Oil Filter Valve
17-Jacking Boss
18-Stopper
19-Foundation Bolt
20-Grounding Pad
21-Base
22-Coil
23-Coil Pressure Plate
Fig. 2.2-1 3-f Power Transformer 24-Core
25-Terminal Box for Protective Device 29-Manhole
26-Nameplate 30-Hanger
27-Dia1 Thermometer 31-Dial type Oil Level Gauge
28-Radiator
The three phase Power transformers installed in transmission sub stations are normally
constructed and operated at the higher voltages in the range of primary 380 kV, 115
kV/69 kV.
145

CONSERVATOR
The conservator or expansion tank system is
the first transformer oil preservation system.
The oil surface area in contact with the air is
at a minimum and is relatively cool,
minimizing sludging. The connecting pipe
between the conservator and main tank is of
a small diameter inhibiting interchange of
oil between them. Oil in the transformer is
always under a positive pressure and the Fig. 2.2-2 Conservator Expansion
tank is completely filled with oil, as shown Tank
in Fig. 2.2-2.
NITROGEN BLANKET
There is a Nitrogen (N2) blanket put into the sealed tank type transformer, which is
used to keep moisture out and pressure up .
SEALED TANK TYPE NITROGEN BLANKET

Fig. 2.2-3 shows the construction of this system.
Fig. 2.2-3 Sealed Tank Type Power Transformer
146

PRESSURE RELIEF VENT

The relief vents are provided for releasing the abnormally high gas pressure produced
in the oil because of arcing. When the transformer develops trouble, limit the
possibility of tank rupture. The simplest form of pressure relief vent is the rupturing
diaphram at a predetermined pressure. This type of vent is shown in Fig. 2.2-4.
Fig. 2.2-4 Pressure Relief Vent
BREATHERS
All power transformers other than totally sealed types have a Breather. As the liquid
expands and contracts due to temperature cycling, air must be permitted to enter or
leave the Conservator tank. The simplest Breather contains a f ilter to prevent moisture
from entering the transformer. Silicagel crystals are one example of the drying reagent
used in dehydrating Breathers.
Fig. 2.2-5 Breathers
147

These crystals are blue in color when dry and turn pale pink as they become moisture
laden, at which time they should be removed and/or dried. Fig. 2.2-5(a) shows the
positions of a dehydrating Breather in the transformer (Mitsubishi type) and Fig. 2.2-
5(b) shows the construction of dehydrating Breather .
WINDING TEMPERATURE INDICATORS

Fig. 2.2-6 shows different types of
winding Temperature indicators
commonly used to measure the winding
temperature.
(a) (b)
(c)
Fig. 2.2-6 Winding Temperature Indicators
TOP OIL THERMOMETER

Dial-Type Thermometer, as shown in Fig. 2.2-7, is provided to measure the maximum
oil temperature in the upper part of the tank. The dial-type thermometer has alarm
contacts connected to a switchboard -mounted alarm device that sounds whenever the
oil temperature exceeds the specified level. In addition, the thermomet er controls the
on-off cycle of the motor fans to control the oil temperature.
Fig . 2.2-7 Dial-Type Thermometer
148

BUSHINGS
High voltage terminals of the transformer need insulators to insulate high voltage from
ground. These insulators are called Bushings.
Maintenance of Bushings
For oil-filled bushings, the oil level can be
checked through the oil -filling plug or sight glass,
as shown in Fig. 2.2-8.
Fig. 2.2-8 Oil-Filled Bushings

BUCHHOLZ RELAY
Buchholz relay is designed to give a signal when the transformer develops internal
trouble since all faults due to low oil in the transformer result in the localized heating
and breakdown of the oil due to winding faults, causing oil decomposition and will
release gases. Buchholz relay is actuated by the buoyancy of the gas produced in the
transformer or the rushing current of the oil. It is possible to determine the cause of
trouble by checking the quality and color of the gas and quantity in Fig. 2.2-9.
Fig. 2.2-9 Buchholz Relay
149

TRANSFORMER COOLING METHODS

The following Table 2.2-1 shows various methods of cooling transformers according
to British Electrical Standards Association (BESA), American National Standards
Institute (ANSI) and Canadian Standards Association (CSA).
Cooling System in Transformers

Most transformers are immersed in a liquid dielectric, particularly the oil-immersed
transformer cooled by air. The dry-type transformer is simpler in principle. The
transfer of heat from the active part to air takes place in two stages, firstly from the
active part to the oil inside the tank and then from the oil to the air in the cooler. The
movement of fluids either takes place naturally by convection or is forced by pumps
or fans. Table 2.2-1 shows various types of cooling systems each with characteristics .
Table 2.2-1 Cooling System Methods

Type of Cooling Agent Symbol
Mineral Oil O
Gas G
Water W
Air A
Solid insulant S
Type of Circulation Symbol
Natural N
Forced F
Directed through the winding D
Most Common Systems Symbol
Dry Transformer With Natural Cooling In Air AN
Dry Transformer With Forced Air Cooling AF
Transformer With Natural Circulation Of Air and Oil ONAN
Transformer With Natural Oil Circulation and Forced Air Circulation ONAF
Transformer With Forced Oil And Air Circulation OFAF
Transformer With Forced Air Circulation And Directed Oil Flow Through The Windings ODAF
Transformer With Forced Oil And Water Circulation OFWF
150

Transformer Radiator and Cooling Fans (Fig. 2.2-10)

Radiators are used in the transformer to provide cooling
of the oil. Fans are mounted on the transformer
radiators to provide forced air increas ing cooling of oil.
These fans cause a faster heat exchange and will
improve the transformer capability and, in this case, the
transformer can be loaded from 20-30% over the one
used without cooling fans. The fans operate
automatically when the temperature of the oil exceeds
Fig. 2.2-10 Forced Circulation
definite value. For the transformers utilizing forced oil-
of Oil and Air System
forced air for cooling, there is an oil pump; as shown.
Natural Circulation of Oil and Air

Temperature distribution is measured in the direction of heat flow and fluid flow. The
heat is generated in a uniform manner and transmitted by conduction. At the surface
of the windings, in the adjace nt layer of oil, a sharp temperature drop occurs, which is
a function of the surface density of heat loss and the fluid velocity. Outside this zone,
the temperature drops only little. A similar change occurs in the magnetic circuit and
its cooling ducts.
Forced Circulation of Oil and Air

More intense cooling of the oil increases its viscosity, restricting circulation of the oil
and limiting the increase in power. To obtain better performance, an oil circulation
pump must be used. The circulation of oil within the windings always occurs by
convection, as shown in Fig. 2.2-9 and 2.2-10 and the oil circulated by the pump flows
in the tank around the outside of the windings. The final step is to channel the oil
leaving the cooler so that it flows towards the base of the magnetic circuit and the
windings. The velocity of the oil in the windings is increased tenfold from which
practically doubles the coefficient of heat transmission. This arrangement is used
more and more in medium power transformers from 10 to 100 MVA and is almost
universally used in high power transformers above 100 MVA.
151

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152

LESSON 2.3
POWER TRANSFORMER TESTS
153

154

LESSON 2.3
POWER TRANSFORMER TESTS
LESSON OVERVIEW
DESCRIPTION
In this lesson, different tests are carried out to check the transformer and cooling
oil during the service period and the results are compared with normal manufacturer's
test standard data as part of regular maintenance.
OBJECTIVES

∑ Determine the winding polarities of power transformers.
∑ Familiarize with different transformer connection diagrams.
∑ Perform different transformer and oil tests.
∑ Determine the Transformer Turns Ratio using different test methods and test
equipment.
TRANSFORMER TESTS
Different tests are carried out to check the transformer characteristics, as shown
in Table 2.3 -1.
Table 2.3 -1 Transformer Tests
1. Ratio test 2. Polarity Test
3. Impedance Test 4. Insulation Resistance
5. Resistance of Winding 6. No Load Losses Test
7. No Load Current Test 8. Core Insulation Voltage Test
9. Temperature Rise Test 10. Impulse Voltage Test
11. Noise Level Test 12. High Voltage Test
13. Induced Voltage Test 14. Bushing Power Factor Test
155

TRANS FORMER POLARITY TESTI NG FOR SINGLE -PHASE

TRANSFORMER
Polarity tests are made to determine how the coils of a transformer are wound in
relation to each other so that the direction of the secondary voltage may be known
when connecting transformer in parallel or in polyphase. Fig. 2.3-1 illustrates the
method used to determine polarity marking s.
X2 X1 X1 X2
20 V 20 V
80 V V V
120 V
100 V 100 V
H2 H1 H2 H1
(a) Subtractive (b) Additive
Fig. 2.3-1 Method used to determine Polarity Markings
THREE -PHASE TRANSFORMER CONNECTIONS

Connecting the primary and secondary windings in Y and Δ combinations will
provide a variety of transformer conditions for specific applications.
Winding Identification Letters
Identification Letter
Vector D iagram Method of Connection
L V Side HV Side
Delta Δ D d
Star Y Y y
156

TRANSFORMER TURNS RATIO TEST USING TTR SET

The most well known method of checking turns
ratios in the field utilizes the Transformer Turns
Ratio (TTR) Test Set, as shown in Fig. 2.3-2. This
test set has an internal alternator to supply the test
potential. The ratio of a standard transformer in the
test set is adjusted until its voltage is exactly equal
to transformer under test. The ratio of the standard
transformer then indicates the ratio of the
transformer under test. Fig. 2.3 -2 Transformer Turns Ratio
Test
The measured ratio
should compare
with the nameplate
ratio to within ±
0.5 %. For 3-phase
transformer ratio
tests, use the
connections in Fig.
2.3-3(a-e) with
TIR set.
Fig. 2.3-3(a-e) 3-Phase Transformer Connections

For 3-phase transformer test, ratio meter H2
V2
X2
or voltmeter method is used, as shown in AC 3 f V1
220 V
HO V1
Fig. 2.3-4. The 220V three-phase shall be X1 Voltage Ratio=
V2
H1 H3
applied to the high voltage winding and X3
voltage between line terminals of high

Fig. 2.3-4 3-Phase Transformer Test with Ratio
voltage winding and low .voltage winding Meter
are measured.
157

I1 ¥ N1 = I2 ¥ N2 Where: V1 = Primary voltage

I1 N2 V1Z1 V1 Z2
V2 = Secondary voltage
= = = ¥ I1 = Primary current
I2 N1 V2 Z2 V2 Z1
I2 = Secondary current
N1 = Primary Turns
N2 = Secondary Turns
Z1 = Primary impedance
Z2 = Secondary impedance
WINDING RESISTANCE TESTS

The DC resistance of both HV and LV R
K2
A
windings can be measured simply by
V
Voltmeter/Ammeter method, as shown BATTERY K1 WINDING
in Fig. 2.3-5.
Fig. 2.3-5 Voltmeter/Ammeter Method
INSULATION RESISTA NCE TEST

Insulation resistance tests are carried out on all windings, core and core clamping
bolts. They are measured in Mega Ohms (MW) as an indication of the transformer's
ability to withstand its rated voltage without grounding or shorting due to insulation
breakdown. Megger is used to measure insulation resistance. The insulation resistance
of a transformer should be at least 1 MW for each 1000 Volts of test voltage. If it falls
below this figure, presence of dirt or moisture may be indicated. The tests are
performed between:
∑ H V windings to ground
∑ L V windings to ground
∑ HV windings to LV windings
All test readings should be recorded for comparison with past results. Insulation
deteriorates with time and test readings are means for monitoring the conditions of
transformer insulation over time.
158

TRANSFORMER OIL
Power transformers are mostly cooled by oil and usually the first thing checked in
determining the condition of a transformer is the oil. In a transformer, oil not only acts
as insulation but also provides a medium carrying heat away from the windings.
Hence, it should not only have high dielectric strength, but should also have low
viscosity to provide good heat transfer. It should also be free of sulphur and other
corrosive agents, which might injure the insulation, conductors and other metallic
parts. It should not permit moisture particles to remain in suspension but allow them
to settle quickly to the bottom, and it should be free from sludging under normal
operationing (heat) conditions.
CHARACTERISTICS OF TRANSFORMER OIL

Neutralization value (acid #) (According to British Standards) <0.03 mg
KOH (milligram potassium hydroxide)/gram oil
∑ Sludge value (maximum) 0.1%
∑ Flash Point (minimum) 140°C
∑ Viscosity at 20 0C <25°C. St =25 x 10-6 m2/sec
∑ Pour point -40°C
∑ Dielectric strength (2.55 mm spacing) >30 kV (55 kV , IEC standard)
∑ Density at 200c 0.895 g/cm3
PRECAUTIONS FOR SAMPLING OIL

WARNING
Do not attempt to sample oil from energized sealed transformers. Always
disconnect sealed transformer from HV an d LV sides before oil sampling.
OIL TESTS
∑ Appearance test ∑ Color test ∑ Odor test
∑ Interfacial tension test ∑ Crackle test ∑ Neutralization test
∑ Dielectric breakdown voltage test ∑ Dissolved gas-in-oil analysis test
159

APPEARANCE AND COLOR TEST

Examine on a glass slide a thick layer (e.g. 100
mm) of oil. The oil should be clear, not
excessively dark in color and without visible
contamination. The color test is performed by
comparing the color of the sample with a panel of
several standard colors in the coil color test set,
as shown in Fig. 2.3-6. The Crackle Test will
detect the presence of undissolved water in oil.
Pour enough oil into a clean dry test tube. Fig. 2.3-6 Oil Color Test Set
Heat the sample rapidly over until it begins to boil. If any audible crackling occurs,
this indicates the presence of moisture.
For this test, motorized oil set test kit is used, as shown in Test Kit of Fig. 2.3-7. The
oil is tested between two, one inch diameter circular electrodes set in a standard test
cup. The electrodes are usually set with spacing between them of 2.5 mm and these
electrodes are parts of an adjustable AC high potential test set.
1. Mains supply switch
2. Mains on indicator lamp
3. Manual auto switch
4. HV indicator lamp
5. Auto start push button
6. HV over load switch
7. Speed selector switch
8. Voltage control hand wheel
9. Mains fuse
10. Scale
11. Oil drip tray
12. Electrode Supports
13. Electrode
14. Cover
Fig. 2.3-7 Oil Tester
160

BREAKDOWN VOLTAGE TEST

The minimum breakdown voltage for new oil for a transformer is 30 kV/2.5mm or
120 kV/cm. The minimum breakdown voltage for service oil is 22 kV/2.5mm or
88kV/cm. For oil testing less than 20 kV, oil should be removed from the tank and
filtered through filter press paper or centrifugal before putting back into the tank .
TEST RESULT GUIDE (SEC STANDARD -SMS -IIOI-03-T)
Table 2 . 3 - 2 Guide for Acceptable Oil Test Results
SUMMARY
∑ The insulation resistance of a transformer should be at least 1 MW for each 1000
Volts of test voltage.
∑ In a transformer, oil acts as insulation and also provides a medium for heat tra nsfer
from the windings for cooling.
∑ Do not attempt to sample oil from energized sealed transformers.
GLOSSARY
TTR: Transformer Turns Ratio HV: High Voltage
LV: Low Voltage PPM: Parts per Million
FORMULAS
I1 ¥ N1 = I2 ¥ N2
I1 N2 V1Z1 V1 Z2
= = = ¥
I2 N1 V2 Z2 V2 Z1
161

REVIEW EXERCISE
1. The insulation resistance of a transformer should be at least _______ for each 2000
Volts of test voltage.
a) 1 KW b) 2 MW
c) 1 MW d) 2 KW
2. If the insulation resistance of a transformer falls below 1 MW for each 1000 Volts
of test voltage, the presence of ________ or ________ _____ may be indicated.
3. There is no need to disconnect sealed transformer from HV and LV sides before

oil sampling.
a) True b) False
4. The three major types of transformer tests performed, are:

a) b)
c)
162

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164

UNIT-3
TRANSMISSION SUBSTATIONS
165

166

UNIT-3
TRANSMISSION SUBSTATIONS
UNIT OVERVIEW
DESCRIPTION
This unit consists of t wo lessons as follows :
Lesson 3.1 Transmission Substation Components, Operating Voltages and Diagrams

This lesson describes the SEC transmission substation components including switchgear,
transformers and relays. Also this lesson will mention the transmission substation operating
voltage (115 kV, 230 kV and 380 kV) with layout and single line diagrams. The lesson
concludes with different types of transmission towers, lines and protective equipment/devices.
Lesson 3.2 Busbars and Circuit Breakers

This lesson describes the Single and Sectionalized Busbar System, Main and transfer Bus,
Ring and Double Bus and different types of Circuit Breakers.
OBJECTIVES
Upon completion of this unit the participants should be able to familiarize with:
∑ Transmission Substation Components, Operating Voltages and Diagrams
Components: Switch Gear, Transformer, Relays
Operating Voltages: 115, 230, 380 kV
Diagrams: Layout and Single Line Diagrams
Transmission Towers/Lines and Maintenance
Standard Poles, Towers and Switchyard Structures, Steel Towers, Overhead
Transmission Lines (115, 230, 380 kV), Substation Switchyard
∑ Busbars and Circuit Breakers

Busbars: Single and Sectionalized Busbar System, Main and transfer Bus, Ring and
Double Bus, Breaker one and Half breaker Design, Switchgear
Identification
Circuit Breakers: Bulk, Air, Gas, Vacuum Circuit Breaker, Breaker Operating
mechanism, Breaker Motion Analyzer
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168

LESSON 3.1
TRANSMISSION SUBSTATION
COMPONENTS, OPERATING
VOLTAGES AND DIAGRAMS
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170

LESSON 3.1
TRANSMISSION SUBSTATION COMPONENTS,
OPERATING VOLTAGES AND DIAGRAMS
LESSON OVERVIEW
DESCRIPTION
This lesson describes the SEC transmission substation components including

switchgear, transformers and relays. Also this lesson will mention the transmission
substation operating volta ge (115 kV, 230 kV and 380 kV) with layout and single line
diagrams. The lesson concludes with different types of transmission towers, lines and
protective equipment/devices.
OBJECTIVES

∑ Identify components of transmission substation ( Switchgear/Transformer/Relays).
∑ Identify operating voltages of transmission substations (115/230/380 kV).
∑ Overview layout and single line diagrams for transmission substations.
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172

TRANSMISSION SUBSTATION COMPONENTS

A substation, as shown in Fig. 3.1-1, is a high -voltage electric system facility used to
switch generators, equipment and circuits or lines in and out of power system. It is
also used to change AC voltages from one level to another and/or change alternating
current to direct current or direct current to alternating current. Some substations are
small with little more than a transformer and associated switches. Others are very
large with several transformers and dozens of switches and other equipment.
Fig. 3.1-1 Typical Substation
SUBSTATION TYPES
Although, there are generally four types of substations, there are substations that are
combinations of two or more types:
1. Step-up Transmission Substation
2. Step-down Transmission Substation
3. Distribution Substation
4. Underground Distribution Substation
1- STEP-UP TRANSMISSION SUBSTATION
The Step-Up Transmission Substation (Fig. 3.1-2) receives electric power from a
nearby generating power plant and uses a large power transformer to increase the
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voltage for transmission to distant locations. A transmission bus is used to distribute

electric power to one or more transmission lines. There can also be a tap on the
incoming power feed from the generation plant to provide electric power to operate
equipment.
High voltage (HV) AC 69 kV, 115 kV, 138 kV, 161 kV, 230 kV
Extra-high voltage (EHV) AC 345 kV, 500 kV, 765 kV
Ultra-high voltage (UHV) AC 1100 kV, 1500 kV
Direct-current high voltage (DC HV) ±250 kV, ±400 kV, ±500 kV
Fig. 3.1-2 Step-Up Transmission Substation
A substation can have Circuit Breakers that are used to switch generation and
transmission circuits in and out of service as needed or for emergencies requiring
shut-down or redirection of power to a circuit. The specific voltages leaving a step -up
transmission substation are determined by the cu stomer needs of the utility supplying
power and to the requirements of any connections to regional grids. The typical DC
voltage is either positive or negative polarity. A DC line has two conductors, one
positive and the other negative.
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2- STEP-DOWN TRANSMISSION SUBSTATIONS

Step-down transmission substations (Fig. 3.1-3) are located at switching points in an
electrical grid. They connect different parts of a grid and are a source for sub-
transmission lines or distribution lines. The step-down substation can change the
transmission voltage to a sub-transmission voltage, usually 69 kV. The sub-
transmission voltage lines serve as a source to distribution substations. Sometimes,
power is tapped from the sub-transmission line for use in an industrial facility along
the way. Otherwise, the power goes to a distribution substation.
Fig. 3.1-3 Step-Down Transmission Substations
3- DISTRIBUTION SUBSTATIONS
Distribution substations (Fig. 3.1-4) are located near to the end-users. Distribution
substation transformers change the transmission or sub -transmission voltage to lower
levels for use by end-users. Typical distribution voltages vary from 34,500 Y/19,920 V
to 4,160Y/2400 V. The 34,500 Y/19,920 V is interpreted as a three-phase circuit with a
grounded neutral source.
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Fig. 3.1-4 Distribution Substation
This would have three high-voltage conductors or wires and one grounded neutral
conductor, a total of four wires. The voltage between the three phase conductors or
wires would be 34,500 Volts and the voltage between one phase conductor and the
neutral ground would be 19,920 Volts. From here the power is distributed to
industrial, commercial and residential customers.
4- UNDERGROUND DISTRIBUTION SUBSTATIONS

Underground distribution substations (Fig. 3.1-5) are also located near the end-
users. Distribution substation transformers transform the sub -transmission voltage s to
lower levels for use by end-users. Typical distribution voltages vary from
34,500Y/19,920 Volts to 4,160Y/2400 Volts.
Fig. 3.1-5 Underground Distribution Substation
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Substations are designed to accomplish the following functions, although all

substations not having all these functions :
1. Change voltages from one level to another.
2. Regulate voltages to compensate for system voltage changes.
3. Switch transmission and distribution circuits into and out of the grid system.
4. Measure electric power qualities flowing in the circuits.
5. Connect communication signals to the circuits.
6. Eliminate lightning and other electrical surges from the system.
7. Connect electric generation plants to the system.
8. Make interconnections between the electric systems of more than one utility.
9. Control reactive kilo-Volt-Amperes supplied to and the flow of reactive kilo-
Volt-Amperes in the circuits.
SUBSTATION COMPONENTS
The major components of a typical substation are, as shown in Table 3.1-1.
Table 3.1-1 Major Components of a Typical Substation

∑ Air Circuit Breakers ∑ Distribution Buses ∑ Potheads
∑ Batteries ∑ Duct Runs ∑ Power-line Carrier Equip.
∑ Bus Support Insulators ∑ Frequency Changers ∑ Power Transformers
∑ Capacitor Bank ∑ Grounding Resistors ∑ Rectifiers
∑ Circuit Switchers ∑ Grounding Transformers ∑ Relays
∑ Concrete Foundation ∑ High-Voltage Underground Cables ∑ SF6 Circuit Breakers
∑ Conduits ∑ High-Voltage Fuses ∑ Shunt Reactors
∑ Control House ∑ Lightning Arresters ∑ Steel Superstructures
∑ Control Panels ∑ Manholes ∑ Supervisory Control
∑ Control Wires ∑ Metal-clad Switchgear ∑ Suspension Insulators
∑ Converter Stations ∑ Meters ∑ Synchronous Condensers
∑ Coupling Capacitors ∑ Microwave Comm. Equip. ∑ Transmission Buses
∑ Current Transformers ∑ Oil Circuit Breakers ∑ Vacuum Circuit Breakers
∑ Disconnect Switches ∑ Potential Transformers
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CIRCUIT BREAKER
The Circuit Breakers (Fig. 3.1-6) are simple
devices, which cut off the power circuit whenever
the current jumps above a safe level until the
electrical personnel on duty can fix the problem .
Fig. 3.1-6 Air Circuit Breaker
POWER TRANSFORMERS
Power transformers (Fig. 3.1-7) are used to

transform the voltage from one level to
another (step up or step down) and regulate
the voltage level.
Fig. 3.1-7 Power transformers

PROTECTION RELAY
Protective Relay (Fig. 3.1-8) is an electric device
designed to respond to sudden faults and operates
a Circuit Breaker to open the circuit and prevent
from destroying the electrical system.
Fig. 3.1-8 Protective Relay
STANDARD POLES, TOWERS AND SWITCH YARD STRUCTURES

Wooden poles and steel towers (Fig. 3.1-9) are used for conductors carrying power
between sending and receiving ends in both distribution and transmission networks.
Wooden poles are widely used for OH distribution lines (LV 13.8/34.5 kV) and in
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OH transmission lines (69/115 kV). Steel towers are used for transmission lines
(69/115/230/380 kV). In some cases, wooden poles are carrying some of the
distribution line equipment, such as transformers, fuse cutouts, voltage regulators.
Fig. 3.1 -9 Different Types of Poles, Towers and Switchyards
SWITCHYARDS
Switchyards (Fig. 3.1-10) are the places where a transmission line terminates to
buses as an outgoing or incoming line or terminates to an equipment bushing. The
following figures show examples of wooden poles, transmission towers and
switchyard structures.
Fig . 3.1-10 Switchyard
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POWER DELIVERY
Electric power leaves the power plants and moves through a complex network of
overhead power lines and underground cables to reach the customers (Fig. 3.1-11).
Fig. 3.1-11 Power Delivery

When electricity leaves a power plant:
1. Its voltage is increased at a " Step-Up Substation".
2. Next, the energy travels along a transmission line to the required area where the
power is needed.
3. Once there, the voltage is decreased at "Stepped-Down Substation" routing
through distribution power line and.
4. Finally, carries the electricity until it reaches a home or business.
SEC strives to maintain steady state voltage within limits established by the SEC
standards. However, all electric distribution systems are subject to occa sional voltage
variations. These variations, even when within limits, can cause the sensitive electrical
equipment within your facility to operate incorrectly. Our electric system is designed
to sense unsafe or unstable conditions that affect the flow of electricity on a power
line, such as certain power quality events caused by acts of nature or construction
mishaps.
When the distribution system senses a disturbance, the electric current is automatically
interrupted by a device called Recloser, which is si milar to a fuse or Circuit Breaker.
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In most instances, within a few seconds, this electrical device will safely reclose the
circuit to restore power and help isolate the effect. Occasionally, the device will
reopen because the problem still exists or because the devices still sense unsafe
conditions, causing momentary interruptions and flickering lights. The overall
reliability of the circuit is actually increased when Reclosers are used. The operation
of such devices means that the system is operating effe ctively. Without these devices,
a power interruption would continue until a utility employee could manually restore
the power.
The technical staff is working hard to eliminate as many of the causes of these
interruptions as they can. In addition to performing upgrades to the equipment, they
are involved with major tree trimming initiatives to lessen the likelihood of storm-
related outages. They are also coordinating with construction contractors to educate
them on the safe and proper excavation methods to use around our buried
underground lines.
SUMMARY
∑ A substation is a high-voltage electric system facility used to switch generators,
equipment and c ircuits or lines in and out of power system.
∑ A transmission bus is used to distribute electric power to one or more transmission
lines.
∑ The Step-down transmission substations are located at switching points in an
electrical grid connecting different parts of a grid sourcing power to sub-
transmission lines or distribution lines.
∑ The sub-transmission voltage lines serve as a sour ce to distribution substations.
∑ The Distribution substation transformers transform the sub -transmission voltage to
lower levels for use by end-users varying from 34,500 Y/19,920 Volts to
4,160Y/2400 Volts.
∑ Switchyards are the places where a transmission line terminates to buses as an
outgoing or incoming line or terminates to an equipment bushing.
GLOSSARY
OH: Over -Head EHV: Extra-High Voltage
LV: Low Vol tage UHV: Ultra-High Voltage
HV: Hi gh Vol tage
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REVIEW EXERCISE
1. The four types of substations are :
a) b)
c) d)
2. The power can be tapped from the incoming power feed from the generation plant
to provide electric power to operate equipment.
a) True b) Fal se
3. The step-down substation can transform the transmission voltage to a sub-

transmission voltage level, usually _______ kV.
a) 69 b) 13. 8
c) 34. 5 d) 19. 92
4. Distribution substations are located near the ___________.

a) End-users b) Grid st at ion
c) Power pl ant d) Transmi ssi on subst at ion
5. Li st four maj or types of subst at ion equi pment /prot ecti ve devi ces.
a) b)
c) d)
6. Enlist the sequential electric power flow when electricity leaves a powe r plant:
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184

LESSON 3.2
BUSBARS AND CIRCUIT BREAKERS
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186

LESSON 3.2
BUSBARS AND CIRCUIT BREAKERS
LESSON OVERVIEW
DESCRIPTION
This lesson describes the Single and Sectionalized Busbar System, Main and transfer
Bus, Ring and Double Bus concluding with different types of Circuit Breakers and
their applications.
OBJECTIVES
Upon completion of this lesson, the participants should be able to familiarize with:
∑ Busbars
Single and Sectionalized Busbar System, Main and transfer Bus, Ring and Double
Bus, Breaker one and Half breaker Design, Switchgear Identification
∑ Circuit Breakers
Bulk, Air, Gas, Vacuum Circuit Breaker, Breaker Operating mechanism, Breaker
Motion Analyzer
BUSBARS ARRANGEMENT
Different busbar arrangements are used to serve certain requirements for system
operation, protection and to control the power flow, as follows:
1. Single Busbar System
2. Sectionalized Single Busbar
3. Main and Transfer Bus Double Main Bus
4. Ring Bus Design
5. Double Bus and Single Breaker and Half Design
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188

1- SINGLE BUSBAR
Fig. 3.2-1 shows Single Busbar scheme used
for smaller substations. It is to be noted that if
at any time a busbar fault occurs, all feeders
will be deprived of supply.
Fig. 3.2-1 Single Busbar System
Fig. 3.2-2 shows a single line

diagram for a substation
66/13.8kV (AMIR Grid Station-
SEC).
Fig. 3.2-2 AMIR Grid Station-SEC
2-SECTIONALIZED SINGLE BUSBAR
Fig. 3.2-3 shows a sectionalized bus

design. The main bus is split into
two sections bus 1and bus 2 by tie
Circuit Breaker, which is called Bus
Tie.This provides complete
shutdown by one section for
maintenance or repair without Fig. 3.2-3 Sectionalized Bus Design
interfering supply from other
section.
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The multi-sectionalized
busbar is shown in Fig . 3.2-
4. By these means, a
generating plant on any
section can be utilized to
supply the feeders on any
adjacent section. Fig. 3.2-4 Sectionalized Busbar System
3-MAIN AND TRANSFER BUS

A transfer bus is one in which one circuit at
a time can be transferred from the main
bus, as shown in Fig. 3.2-5. The transfer
bus provides a means for servicing the
feeder breaker. During an outage of main
bus equipment, however, the lines can be
transferred to the T-bus. Fig. 3.2-6 shows
an example of two main buses and one
transfer bus used in SEC. Fig. 3.2-5 Main and Transfer Bus
Fig. 3.2-6 Two Main Buses and One Transfer Bus
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4-DOUBLE BUS, DOUBLE BREAKER

The double main bus illustrated by Fig. 3.2-7 (a-b). Each load can be supplied from
either bus. At times, half feeders are fed from bus no. 1 and the other half are fed from
bus no. 2.
(a) (b)
Fig. 3.2-7 Double Bus Double Breaker
Both sets of equipment are usually kept in service at all times. Thus, if either should
fail, interruption does not occur to the connected facilities. Fig. 3.2-8 shows an
example of double ma in bus in SEC.
Fig. 3.2-8 Double Main Bus
191

5-RING BUS DESIGN (Fig. 3.2-9)
Main buses sometimes are arranged in the form of a ring. This provides some of the
reliability of the parallel bus and keeps some of the economy of the radial bus. Instead
of using Circuit Breakers to disconnect each piece of equipment, the breakers are
placed in the RING BUS dividing the rings into sections. Each separate section can
be disconnected and some connected equipment with it without interruption to the
other sections.
Fig. 3.2-9 Ring Bus Design Used In SEC
6- DOUBLE BUS ANDSINGLE BREAKER

Fig. 3.2-10 shows another design named Double Bus Single Breaker. The
arrangement includes bus-tie breaker to connect the main two buses together. This
arrangement allows one feeder to transfer from bus No. 1 to bus No. 2 without
switching the feeder off by using a disconnect switch. All feeders could be supplied
from the main bus No . 1 or half of a feeder could be supplied from feeder No . 1 and
the other half from feeder No . 2.
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Fig. 3.2-10 Double Bus &Single Breaker Design
Fig. 3.2-11 shows an example of Double Bus Single Breaker scheme used in SEC.
Fig. 3.2-11 Double Bus Single Breaker Design
7-BREAKER AND HALF DESIGN

Fig. 3.2-12 shows another design named Breaker and half design , some-times named
three breakers scheme. This scheme includes three breakers. The main two buses and
two feeders are fed from the three breakers; therefore, this scheme is named breaker
and half. Usually all breakers are on and both busses 1 and 2 are energized. In case of
any problems with the buses, all the feeders will be fed from the other bus
automatically.
193

Fig. 3.2-12 Breaker and Half Design
CIRCUIT BREAKERS
Circuit Breakers are classified according to insulation and air extinguishing medium,
as follows:
1. Bulk Oil Circuit Breakers (BOCB) 4. Gas Circuit Breakers (GCB)
2. Minimum Oil Circuit Breakers (MOCB) 5. Vacuum Circuit Breakers (VCB)
3. Air Circuit Breakers (ACB)
A circuit breaker is a mechanical device for opening or closing a circuit s afely under
all abnormal conditions. Circuit breakers can be operated automatically as well as
manually, but for high voltage and heavy current, they are generally spring or
electromagnetically assisted or remote controlled.
Overload trips, generally with some form of
time lag, are fitted so that the circuit breaker
will trip in the event of a serious overload or
a fault. Circuit Breakers are used to protect
the electrical equipment and circuits against
internal or external short circuit and to
provide flexibility of control and operation.
The control circuit for protection is shown Fig. 3.2-13 Protection Control Circuit
in Fig. 3.2-13.
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1- BULKOIL CIRCUIT BREAKERS (BOCB)

The BOCB is the most widely used type of
interrupting device for p ower networks. The medium
of insulation and arc extinguish ing is oil, as shown in
Fig. 3.2-14. Operation of the OCB is initiated,
utilizing direct current by manually or remote
operation of supervisory control equipment or by
relays that automatically recognize pre-determined
conditions or electrical failure in the syst em. Fig. 3.2-14 Three Tank
BOCB (Floor Mounted)
Fig. 3.2-15 shows fixed and moving
contacts. The mechanism and air
operating equipment are enclosed in a
weather-proof housing. The rating of
each CB is shown on the breaker
nameplate. The nameplate is located on
the inside of the operating mechanism-
housing door . The breaker should not be
operated at voltages or currents greater
Fig. 3.2-15 Fixed and Moving Contacts
than those given on the nameplate.
Most CBs are composed of three similar pole-unit assemblies and operating
mechanism. The pneumatic operating mechanism is enclosed in weather proof
housing. The operating mechanism provides a stored energy source for operation of the
breaker, as shown in Fig. 3.2-16.
Fig. 3.2-16 pneumatic operating mechanism
195

2- MINIMUM OIL CIRCUIT BREAKERS

Minimum oil CBs differ from BOCB Fig. 3.2-17.

Fig. 3.2-17 MOCB type TRI
They are reduced in size and oil. Fig. 3.2-18 (a) and (b) shows comparison between
MOCB and BOCB. In the BOCB the tank is "dead" at earth potential and the
necessary clearances for the system voltage must be obtained in oil between live
contact the tank and between other contacts .
In the MOCB, the tank is a tube of
insulating material held between metal and
caps and as these caps are the terminal
points for the external circuit, the tank, in
normal circumstances, is live at line
voltage. Operating mechanism of MOCB is
mostly spring, the spring either manually
charged or charged by motor. The energy
(a) MOCB (b) BOCB
stored in the springs is utilized for both the Fig. 3.2-18
closing and tripping operation.
3- AIR BLAST CIRCUIT BREAKERS

In ABCB, the current interruption is through a powerful blast of air at high pressure
and velocity in the arcing region (Fig. 3.2-19). For BOCB and MOCB, there is no
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external aid required for current interruption. As for air-blast CB, a supply of clean,
dry air at the correct pressure and in sufficient volume must be available at all times.
For this, a compressed air arrangement is essential with duplicate compressors for
security, along with air storage facilities and a network of feed pipes.
Fig. 3.2-19 Air Blast Circuit Breaker Fig. 3.2-20 SF6 Circuit Breaker
4- GAS CIRCUIT BREAKERS
Recently, SF6 gas is used in insulation and extinguishing medium in Circuit Breakers.
SF6 is a colorless and odorless gas. It has excellent dielectric properties. Under
comparable conditions , its dielectric strength is about 2.5 times that of air. SF6 Circuit
Breaker shown in Fig. 3.2-20 has one arcing chamber per pole of the self -generating,
single-pressure design. During the opening sequence, a piston coupled to the nozzle
contacts, generates the SF6 flow required for arc interruption. The 3-pole drive is of
the oil hydraulic design. All ancillary equipment, including the oil pump and
accumulator associated with the drive, form a modular assembly that is mounted
directly on the circuit breaker, thus eliminating installation of hydraulic piping on site.
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5- VACUUM CIRCUIT BREAKERS
A vacuum CB is used in high voltage distribution circuits. The contacts are placed in a
sealed container in a vacuum and they are in the form of flat disks with their faces
together, as shown in Fig. 3.2-21 and Fig. 3.2-22. The moving contact is connected to
the outside operating mechanism by means of metal bellows to maintain the vacuum.
Since the contacts are in a vacuum, there are no particles to cause ionization when the
arc is formed as the contacts part. However, some ionization occurs at the contact
surface, owing to vaporized metal at this point, but the arc is extinguished at the first
current zero after the contacts start opening. Thus the duration of the arcing time being
very short, the contacts being in vacuum there is no oxidization and negligible burning
require no maintenance.
Fig. 3.2-21 Vacuum Circuit Breaker Fig. 3.2-22 Vacuum Circuit Breaker
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6- AIR CIRCUIT BREAKERS

The Air CB is used extensively for medium voltage range up to 650 V and sometimes
in high voltage range up to 13.8 kV.
The Air Circuit Breakers are operated by
spring or solenoid and are equipped with
arching "chute" as shown in Fig. 3.2-23(a).
The contact system is fitted with arc runners
to assist the upward movement of the arc to
the arc chute. In the arc chute, the arc is
lengthened and divided into very short arcs.
The arc will be extinguished easily. Fig. 3.2- Fig. 3.2-23(a) Air Circuit Breakers
23(b) shows the parts of an Air Circuit
Breaker in full detail.
Fig. 3.2-23(b) Parts of Air Circuit Breaker
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TM-1600 CIRCUIT BREAKER ANALYZER SYSTEM

As shown in Fig. 3.2-24, the TM1600™ breaker analyzer measures a circuit breaker’s
timing cycle. The timing channels record closings and openings of main contacts,
resistor contacts and auxillary contacts. Since the timing channels are not
interconnected, you can take measurements of resistor contacts and series connected
breaker chambers without disconnecting them. A built-in program unit permits easy
selection of different sequences of breaker control pulses. The delay time between
pulses is set on a thumbwheel switch. The breaker operation unit can be used to
control coil currents of up to 25A. The time values obtained refer to the exact instant
at which voltage was applied to the coil and a built-in printer provides you with a hard
copy printout immediately after measurement. The TM1600™ can be equipped with
up to 24 time-measuring channels as required by the user. When more than 24
channels are needed, one or several slave units can be connected together to get an
unlimited number of measurement channels.
Modular design also makes it easier to
combine the system with the MA 61™
Motion Analyzer. The TM1600™
supports communication with
personal computers and the CABA
Win™ Breaker Analysis Software.
The analyzer can be used for testing
breakers taken out of service or for
on-line testing. Fully equipped, it
weighs only 12 kg (26.5 lbs). Fig. 3.2-24 TM1600™ Circuit Breaker
Analyzer
MA61 MOTION ANALYZER

The MA61 Motion Analyzer is an excellent supplement to the TM1600. It combines
the easy readability of an oscillograph with the extra accuracy ensured by
computerized measurement and computer-processed readings. Menu-driven button
selection via the built -in display makes operation simple and easy. The MA61 can be
equipped with up to 6 analog channels and it can be easily adapted to the different
200

measurement requirements for high-voltage circuit breaker testing. It can measure and
calculate contact paths and the speeds at which breaker contacts operate as well as the
current in operating coils. It can also measure dynamic resistance (DRM), voltage,
pressure, vibration signals and other analog quantities.
After measurement, the MA61 performs the necessary calculations and prints results
on a connected printer (letter-size A4 paper) or via the TM1600’s built-in printer.
Moreover, parts of curves can be easily enlarged for closer study. The MA61
incorporates a battery-backed memory that can store up to ten measurements for
subsequent processing.
APPLICATION EXAMPLE BREAKER TESTING

Setup
A typical breaker test hookup is shown here.
Preparation
Set the desired breaker operating sequence on the TM1600. In this case, Close-Open
(CO).
Recording
Enable recording with the READY button. Start the breaker sequence and
measurement simultaneou sly by turning the START switch.
Test Report
The result is printed automatically. This example shows a CLOSEOPEN (C-O)
sequence presented in the report 1 format (85 % of actual size). Only the initial
contact closing time (CLOSE) and final contact separation time (OPEN) are presented
in the report 1 format. Short bounces are not shown .
BREAKER TIMING WITH MOTION RECORDING

Setup
Connect the transducers to the breaker.
Preparation of MA61
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The following additional settings are needed when you include motion recording in
breaker analysis. These settings are menudriven via the built-in display on the MA61.
1. Select test interval (50 ms to 1 s).
2. Calibrate the input(s) connected to the position transducer(s) , as follows:
a) Close the breaker.
b) Record closed positio n via menu option.
c) Open the breaker.
d) Record the open position.
e) Estimate or measure breaker stroke. Enter the value via the menu.
f) Enter speed calculation parameters.
3. Enter the current range and the scale factor for the current shunt for current to be
measured.
4. Enter range and scale factor for other transducers , if used.
Recording
Press the READY button to prepare the TM 1600 for measurement.
Travel measurement, time measurement and the breaker sequence all start
simultaneously when you turn the START knob. The inputs now record the input
voltages obtained from the connected transducers.
Test report
The motion recording report includes both curves and a table. The table presents
calculated breaker parameters such as closing speed, opening speed, overtravel and
penetration.
The diagram shows one or more time/amplitude curves and the calculated breaker
parameters. The time axis scale factor can be changed to provide you with a quick
overview of an enlarged view part of diagram.
The position of the curve in the diagram and the amplitude scale factor can also be
changed to make best use of the available space. The damping and speed variations at
closing and opening times can be studied on the speed curve obtained from each of the
motion-monitoring c hannels.
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Fig. 3.2-25 TM1600/MA61 Motion Analyzer
203

Fig. 3.2-26 Printout Test Sheet of TM1600/MA61 Motion Analyzer
204

SUMMARY
∑ Bus-Bars may be in the shape of tubes, bars, pairs or cable.
∑ The bus duct is a sheet metal pipe that supports and protects the heavy, hollow,
square/round copper/aluminum bus.
∑ The bus support insulators and the surrounding duct jacket provide electrical safety
and protection, not only for the bus but also for the plant personnel and equipment.
∑ Circuit breakers (CBs) protect the e lectrical equipment and circuit against internal
or external short-circuits.
∑ The most common five design specifications of Circuit Breakers are:
Voltage Rating, Insulation withstanding voltage, Current rating, Interrupt ratings
and Operating time in Hz.
∑ The oil as an insulator in an OCB and its excellent cooling properties gives greater
current carrying capability in smaller packages.
∑ SF6 gas used in GCBs for insulation and extinguishing medium is a colorless,
odorless, non-toxic, inert and odorless gas having excellent dielectric properties
(2.5 times that of air) under comparable conditions .
GLOSSARY
T-Bus: Transfer Bus. NEMA: National Electrical Manufacturers'
Association.
ACB: Air Circuit Breakers. AIEE: American Institute of Electrical
Engineers.
BOCB: Bulk Oil Circuit Breaker. kVA: kilo-Volt-Amperes.
MOCB: Minimum Oil Circuit Breaker. MVA: Mega-Volt-Amperes.
GCB: Gas Circuit Breakers.
2.5 FORMULAS
E
I= Where: I = Current E = Applied voltage Z = Circuit resistance
Z
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206

REVIEW EXERCISE
1. Bus-Bars are normally made of _____________ or _______________.
2. An isolated phase bus duct carries each phase of the three-phase generator output
in separate duct.
a) True b) False
3. The high capacity bus ducts often utilize _____________ cooling, where filtered
air is drawn through the duct to increase heat transfer.
4. The British Standards specify that the temperature rise, when carrying normal
rated current at rated frequency, shall not exceed __________°C.
a) 59 b) 75
c) 125 d) 55
5. List at least four types of Circuit Breakers:

a) b)
c) d)
6. Under short-circuit condition of a circuit drawing 2000A current from a 13.8 kV

line voltage, the short -circuit impedance (Z) is _________ W.
a) 6.9 b) 69
c) 2k d) 13.8
7. OCBs suppress the sparks of high voltage better than pneumatically operated Air
Circuit Breakers.
a) True b) False
8. All tanks in BOCB are mounted directly to the floor without insulators and
grounded at 0V potential.
a) True b) False
9. Operating mechanism of MOCB is mostly _______, which is either manually

charged or charged by a motor and the energy stored in the _______ is utilized for
both the closing and tripping operation.
207

10. Identify the two circuit breakers:
______________________________ ______________________________
11. A ____________ is used in high voltage distribution circuits where the contacts
are placed in a sealed container in a vacuum in the form of flat disks with their faces
together.
208

UNIT-4
DISTRIBUTION SUBSTATIONS
209

210

UNIT-4
UNIT OVERVIEW
OVERVIEW
This unit consists of two lessons as follows:
Lesson 4.1 deals with Distribution Substation Types , Components and Voltage Levels
followed by two tasks. This lesson familiarize the participants with distribution
substation equipment, EOS, SF 6 Ring Main Unit (RMU), Lucy switchgear, earth fault
indicators and single line diagrams.
Task 4.1-1: Demonstrate Distribution Network in Outside Yard
Task 4.1-2: Identify secondary and customers distribution equipment
Lesson 4.2 discusses Meter Types and their Classifications and overviews the
operation and maintenance of different types of meters used in power transmission
and distribution systems.
OBJECTIVES
Upon completion of this unit the participants should be able to fa miliarize with:
∑ Distribution substation Types
Room Type Substations, Unit Substation, Lucy RMU and EOS
∑ Components of Distribution network
MV Components, Ring Main Unit (RMU), Earth Fault Indicator (EFI), Substation
Room, Air Switches, Circuit Breakers, Distribution Panel, Overhead Line
Patrolling, Overhead Line Equipment
∑ Inspection and Maintenance of Components of Distribution network
∑ Meter Types and their Classifications
211

212

LESSON 4.1
DISTRIBUTION SUBSTATION TYPES,

COMPONENTS AND VOLTAGE
LEVELS
213

214

LESSON 4.1
DISTRIBUTION SUBSTATION TYPES,
COMPONENTS AND VOLTAGE LEVELS
LESSON OVERVIEW
DESCRIPTION
This lesson familiarize the participants with distribution substation equipment, EOS,
SF6 Ring Main Unit (RMU), Lucy switchgear, earth fault indicators and single line
diagrams.
OBJECTIVES
Upon completion of this lesson, the participants should be able to :
∑ Identify distribution substation equipment.
∑ Trace the single line diagram for unit substation with RMU.
∑ State purposes of RMU and EOS and identify the parts of Lucy switchgear.
∑ State the applications , uses and range of SF6 Ring Main Unit (RMU).
∑ Explain theory of operation of earth fault indicators.
215

216

INTRODUCTION
The distribution system is fed through grid stations. They are of a large capacity and
supply power to a large area through many primary feeders. Each primary feeder is
supplying several distribution substations .The primary and secondary distribution is a
part of the system through which the power finally reaches the industries and
residential consumers . Distribution Substations are those substations, which are
located nearest to the load. The outgoing feeders supply the distribution substation
with 13.8 kV, or 34.5 kV from Grid Station, and reducing the AC power to a level
suitable for distribut ion (220V, 110V).
TYPES OF DISTRIBUTION SUBSTATIONS

There are many types of substations used in primary distribution such as Unit
Substation, Package substation, Room substation, Pole mounted transformer, Platform
mounted transformer, Pad mounted transform er.
There are five types of substations used for primary distribution as follows:
1) POLE MOUNTED TRANSFORMERS - PMT (OUTDOOR)
Fig. 4.1-1 shows a pole mounted

transformers. In this type of substation the
high tension is supplied to the
transformers from overhead lines.
Fig. 4.1-1 Pole mounted Transformers
217

2) PLATFORM MOUNTED
TRANSFORMER
Fig. 4.1-2 shows platform mounted

transformers where the high tension is
supplied to the transformer either by
overhead lines or by underground cables
from Ring Main Unit (RMU).
Fig. 4.1-2 Platform Mounted Transformer
3) UNIT SUBSTATION
Unit substations in Fig. 4.1-3 consist of a 13.8 kV/LV distribution transformer with an
integral LV distribution panel.
Unit substations are used to supply LV
network in residential and commercial
areas. The advantage of unit substations is
its compact size, which makes it easier to
obtain sites for installation and easier to
find an area for the LV network with
short LV feeders.
Fig. 4.1-3 Distribution Unit Substation
SINGLE LINE DIAGRAM FOR

UNIT SUBSTATION WITH RMU
Fig. 4.1-4 shows a single line
diagram of 300 kVA unit substation.
Fig. 4.1-4 Single Line diagram Unit

Substation with RMU
218

4) PACKAGE SUBSTATION
Package substation Fig. 4.1-5 used in
SEC where the Ring Main Unit
(RMU), transformer and secondary
voltage distribution cabinet form one
unit.
Fig. 4.1-5 Package Substations
5) ROOM TYPE SUBSTATION

This consists of an indoor switchgear feeding transformers installed in a freestanding
room or a room in consumer’s building. These substations are used for single -point or
multi-circuit LV supply to schools, apartment buildings, commercial buildings,
industrial buildings and compounds. Fig. 4.1-6 shows illustration of indoor
distribution room and equipm ent inside the room.
The main equipment installed in a room -type substation is the transformer, Ring Main
Unit, LV panel, and HV/LV cables. Transformer at room type is a ground-mounted,
500/1000 kVA. RMU is a ground-mounted with two 400 Amps ring switches. LV
distribution panel is fitted with a 1600 Amps isolator for incoming circuit and eight
outgoing 400 Amps each.
Fig. 4.1-6 Indoor Substation
219

LUCY EXTENSIBLE OIL SWITCH (EOS)

The extensible oil switch has provision for solid connection to busbar for two main
cables and an oil switch for isolating the tee -off circuit.
LUCY EOS
All oil switches include fully interlocked earthing and testing facilities for the ring
cables, while the fuse switches have earthing facilities for the tee-off cables or
transformer connection only.
Fig. 4.1-7 incorporates two oil switches for isolation
of the ring main circuit and an oil fuse switch for
controlling the tee-off feeder. Each of the two
switches is a single break, 3-position type On/OFF
and Earth.
Fig. 4.1-7 Lucy EOS
RMU LUCY SWITCHGEAR GROUNDING PROCEDURES

Before attempting any internal inspection, except fuse replacement, on switchgear, the
following grounding operations must be carried out :
∑ The unit must be isolated from all sources of electrical supply.
∑ The unit must be grounded at the remote end of all incoming HV feeders.
∑ Ring Main Unit switches must be opened and grounded.
∑ The transformer switch must be opened and grounded to discharge the HV
windings of the transformer.
∑ LV side of the transformer must be disconnected from the LV panel and
grounded.
SF6 RING MAIN UNIT (RMU)

Sulfur Hexafluoride (SF6) is an inert, heavy gas having good dielectric and arc
extinguishing properties. The dielectric strength of the gas increases with pressure and
220

2
is more than that of electric oil at a pressure of 3 kg/cm . This gas is now being very
widely used in electrical equipment such as HV Circuit Breakers. This gas liquefies at
certain low temperatures, the liqu efication temperature increasing with pressure.
SF6 USAGE PURPOSES

In SF6 switchgear serves two purposes:
1. Insulating gas
2. Switching gas (arc quenching)
Several types of SF6-RMU are filled with SF6 gas. SF6 substations are compact and
are favored for use inside crowded cities. The following properties of SF 6 gas mak es
it unique for application in electrical equipment.
1-Physical Properties
Colorless odorless, non -toxic gas, non-inflammable, inert gas
State: SF6 is a gas at normal temperature and pressure .
Density: SF6 is a heavy gas, with a density five times that o f air at 20∞C and standard
atmospheric pressure .
2-Chemical Properties of SF 6 Gas

∑ Inactive Gas
The chemical inactivity of this gas is advantageous in switchgear. The life of
metallic parts and contacts are longer in SF6 gas. The components do not oxidize
or deteriorate. Hence, mainte nance requirements are reduced.
∑ Moisture is very harmful to the properties of gas
In the presence of moisture, hydrogen fluoride is formed during arcing, which
can attack the metallic and insulating parts in the circuit breaker.
3- Dielectric Properties of SF 6 Gas

∑ Dielectric properties: Dielectric strength of SF 6 at standard atmospheric pressure
is 2.35 times that of air. It is 30% less than that of dielectric oil used in oil circuit
breakers.
221

∑ At higher pressure the dielectric strength of the gas increases.
∑ At pressure about 3 kg/cm2 , the dielectric strength of SF 6 gas is more than that
of dielectric oil. This property permits smaller clearances and small size of
equipment for the same kV.
MERITS OF SF 6 GAS SWITCHGEAR (Fig. 4.1-8)

∑ The size of SF6 switchgear is small.
∑ The gas is non -inflammable and chemically stable. The decomposition products
are not explosive. Hence there is no danger of fire or explosion.
∑ Same gas is recirculated in the circuit; hence req uirement of SF 6 gas is small.
∑ The current carrying capacity of SF6 CB is about 1.5 times that of ACB.
∑ The SF6 RMU is silent and does not make sound during operation .
∑ The sealed construction avoids the contamination by moisture, dust or sand.
∑ The minimum maintenance required is .
∑ SF6 has excellent insulating arc extinguishing peroperties.
∑ No contact replacement required. Contact corrosion is very small due to
inertness of SF6 gas. Hence contacts do not suffer oxid ization.
Fig. 4.1-8 SF6 Gas Switchgear
222

DISTRIBUTION TRANSFORMERS
The transformer is one of the most efficient electrical equipment ever built. Its
purpose is to increase or decrease voltage or current. Briefly, the transformer changes
electric energy to magnetic energy and then back to electric ener gy, by the process of
mutual induction.
In addition to accessory equipment such as fans, pumps, tap changer, counter and
mechanism, there are various gauges to be read and logged, such as temperature,
pressure and oil level gauges. Some transformers also have a breathing system that
must also be inspected during PM checks. Transformers are usually designed for
average required voltage conditions. However, most transformers obtain some
flexibility of operation by having several tap positions available.
This may be done to make up for the voltage drop in the supply or to accommodate a
specified characteristic of the connected load. The winding taps usually are brought
under oil to a rotary dial switch located inside the transformer tank. The rotary switch
changes the taps and is rotated manually by means of a crank or handwheel usually
located at the side of transformer enclosure. Most transformers have a nameplate
nearby indicating the voltage obtained at each tap position. Some positive means
(Lock or bolt) is used to assure that the tap changer cannot be moved accidentally.
Fig. 4.1-9 shows no load tap changer and Fig. 4.1-10 shows internal wiring of
transformer with tap changer.
Fig. 4.1-9 No Load Tap Changer
223

Fig. 4.1-10 Tap Changer Circuit

Fig. 4.1-11 illustrates the
nameplate on a transformer giving
all the pertinent information
required for the proper operation
and maintenance of the unit. The
capacity of a transformer is
limited by the permissible
temperature rise during operation.
Fig. 4.1-11 Transformer Nameplate
LV PANEL
Fig. 4.1-12 shows LV panel including the outgoing secondary from LV panel to Mini -
pillars. The LV panel is connected to a nearby distribution transformer.
Fig. 4.1-13 shows a single line diagram of a LV panel. Grounding facilities are
provided in the panel.
Incoming
Fuse
Transformer
Distribution cabinet
Busbar
Outgoing
Fig. 4.1-12 LV Panel Fig. 4.1-13 Single Line Diagram of a LV Panel
224

MINI-PILLARS
Mini-pillars are installed outdoor to receive incoming cables from the LV panels. The
Mini-pillars are capable of accepting up to two 4×300 mm 2 Al cables and five 4×70
mm2 Al cables, Fig. 4.1-14(a-b).
Fig. 4.1-14(a) Fig. 4.1-14(b)
EARTH FAULT INDICATORS

EFFECTS OF FAULT CURRENTS
The magnitude of a fault current is determined by the total impedance in its path. The
fault currents are very high and greater than the normal equipment current. High fault
currents, if allowed to continue, can heat up the equipment and cause :
∑ Costly damage to equipment.
∑ Dangerous fire hazard.
∑ Loss of power supply to the customers.
ROLE OF EARTH FAULT INDICATOR

Earth fault (mainly phase -to-earth) is the most common fault on distribution systems.
The following points are very important:
∑ The faulty section to be disconnected as quickly as possible to minimize the
damage to the system and equipment.
∑ The faulty section to be isolated and restored with a minimum number of
customers affected for a minimum period.
The first point is taken care by the Protection System by initiating tripping action of
the Circuit Breaker (CB). The second point is taken care by the EFIs, when operated
giving indication of flow of an earth fault current through the cable on which they are
225

installed in order to facilitate isolation of faulty sections. It is to be noted that an EFI

is not meant to initiate any automatic disconnecting action.
VOLTAGE RESET EFI FOR UNDERGROUND SYSTEM

Voltage reset EFIs are installed in 13.8 kV U/G networks, mostly installed on 3-core
power cables. These operate when earth fault current passes through CT. On
restoration of the supply, the EFI will reset, automatically.
PRINCIPLE OF EFI OPERATION

A schematic diagram of EFI connection to
RMU cable is shown in Fig. 4.1-15. When
there is a phase-to-ground fault on a 3-f
system, it causes an unbalanced current in
each phase. When a CT is installed around
the three cores of the three phase cable, the
unbalanced situation produces a resultant
flux in the CT core inducing current in the
Fig. 4.1-15 EFI Schematic Diagram
CT coil that flows through the EFI current
coil.
LUCY EPIC EARTH FAULT INDICATOR

The EFI includes a magnetic armature relay and when there is a current flowing
through its coil, it actuates a drop -down flag providing two stages of indication. Stage
1 indicates the presence of an earth fault condition and stage 2 indicates the
subsequent clearance of fault by disconnection. There is a voltage coil ( Fig. 4.1-15),
connected to a LV source supplied through the RMU on which the EFI is installed.
Prior to the fault when the conditions were normal, the contact on the voltage coil
circuit is open. On operation of the EFI, the contact is closed by the action of the
attracted armature. However, the immediate tripping of the feeder Circuit Breaker,
prevent supply to the voltage coil. On subsequent restoration of supply, the voltage
coil becomes energized and re-actuates the armature, which in turn resets the
indicator.
226

FLAG INDICATION
Fault indication is by a moving flag visible through a transparent plastic window.
Partially dropped flag indicates a flow of fault current , Fig. 4.1-16. The flag will drop
completely when the fault is isolated. When supply is restored, the indicator will reset,
automatically. Type 'A' Reset Indicators
are provided with a hand reset option. It
is operated by means of a push-button
located in the EFI case. Type 'B'
indicators are provided with automatic Fig. 4.1-16 Positions of Flag
reset.
MV CIRCUIT BREAKERS AT GRID STATION FOR FEEDERS

Circuit Breaker is one of the major equipment used in substations and Grid
substations from different manufacturers. For example , there is Vacuum CB made by
ASEA. S&S, SF6 CB and Type HB by BBC.
13.8 kV SWITCHGEAR TYPE VHE 12 ASEA (Fig. 4.1-17, 18)

VHE is a standard 12 kV metal-enclosed switchgear, used in Grid Station s, made up
of components to form various types of cubicle s. The cubicles are divided into a high
voltage section and a low voltage section. The high voltage section accommodates the
busbars and the switching devices. A window is provided in the cubicle door through
which the position of the switching devices can be checked. The LV section,
completely separated from the HV section, is housed in a metal -enclosed terminal box
that has space for relays and instruments. Terminal blocks and fuses can be mounted
inside the box.
227

Rated Voltage: 12 kV
Rated Current – Busbars: 2500 A
Rated Current - Circuit Breaker: 2500A
VACUUM CIRCUIT BREAKER TYPE HCA (Fig. 4.1-18)

This CB is installed in VHE type indoor switchgear, Rated voltage 12-24 kV, rated
current 1250-2500 A.
SWITCHGEAR TYPE HB (BBC) ON 13.8 kV SIDE (Fig. 4.1-19)

Switchgear type HB is metal clad type for
indoor use designed for 13.8 kV. The CB
is of the SF 6 type mounted in the carriage
of horizontal draw-out type. The carriage
can be moved in and out with motor
drive. This improves the service
availability and operational safety
reduces servicing and maintenance of the
switchgear, substantially.
Fig. 4.1-19 ABB SF6 MV Circuit Breaker
228

GAS CIRCUIT BREAKER TYPE 30 SF 6 (MITSUBISHI)

Gas circuit breaker Type 30 SF6 shown in
Fig. 4.1-20 is draw-out type filled with SF 6
gas.
Fig. 4.1-21 shows the gas circuit breaker
inside the switchgear and Fig. 4.1-22
shows the parts of the Circuit Breaker.
Fig. 4.1-20 Type 30 SF6 CB
Fig. 4.1-21 Gas CB Type 30 SF6 (Mitsubishi Inside the Switchgear)
Fig. 4.1-22 CB Parts

INTERRUPTING UNIT
The interrupting unit (Fig. 4.1-23) consists of a fixed contact, a moving contact, a
movable cylinder and a fixed piston.
229

For the interruption of the breaking

current, the moving contact opens and
then the breaking arc is drawn
between the fixed and the moving
contacts. At the same time, the
cylinder moves and compresses the
gas to generate a temporary
pressurized gas for effective arc
quenching.
Fig. 4.1-23 Interrupting Unit

The compressed gas puffs (blows) on the breaking arc through the nozzle to
extinguish it quickly. This is the principle of the puffer -type interrupting unit.
ARCING COLUMN
The interrupter is a single pressure type that consists of cylinder and a piston as
shown in Fig. 4.1-23. The arcing column is shown in Fig. 4.1-24. The arcing chamber
of each pole unit consists of a cylindrical arcing tank and two bushings , comprising a
pressurized chamber as a whole.
Fig. 4.1-24 Arcing Column
230

INSPECTION & MAINTENANCE OF DISTRIBUTION

SUBSTATIONS
Preventive Maintenance (PM) programs for distribution substations, overhead lines
and equipment are designed to achieve the following goals :
1. Reduce hazard to life and property due to equipment failure.
2. Provide safe and reliable power supply to Customers minimizing power
interruptions due to equipment failure for lack of maintenance.
3. Attain expected lifetime operation of distribution equipment, thus provid ing
reasonable return on capital.
4. Develop statistics on distribution equipment or component performance to
improve system safety and reliability.
Manual (DMM-01-01) provides general guidelines for the inspection and maintenance
of substation equipment on distribution feeders rated 34.5 kV or below consist of any
of the following:
1. Ground mounted substations, indoor and outdoor, with RMUs.
2. Ground mounted package substations with MV air break switchgear
3. Ground mounted compact substations with MV switchgear.
4. Pole mounted substations with transformer on a platform and controlled by an
RMU or Cutout Fuses.
Table 4.1-1 Guidelines for Inspection and Maintenance of Substation Equipment.
231

232

RMU SWITCHGEAR INSPECTION AND MAINTENANCE

information on the planned Inspection and Maintenance of 11/13.8 kV RMU
switchgear. Preventive Maintenance is th e practice of conducting routine inspections,
tests and the servicing of power distribution facilities, consistent with good
economics, so that impending faults can be detected and reduced or eliminated. Whilst
equipment deterioration is normal, equipment failure is not inevitable.
MINI-PILLAR INSPECTION AND MAINTENANCE

The Distribution Maintenance Manual (DMM-02-05) sets out a guideline and
procedure for inspection and maintenance of Mini -pillars in service in order to achieve
reliable performance and opti mum service life.
The Mini-pillar is one of the major components of SEC LV Distribution networks.

Preventive Maintenance is the practice of conducting routine inspections and servicing
of power distribution facilities so that impe nding faults can be detected and reduced or
eliminated.
INSPECTION OF MINI-PILLAR
Routine inspection of each Mini -pillar in service should be carried out as follows:
∑ Costal/High Humidity Areas
Metal enclosure once every four (4) years
Fiber enclosure once every six (6) years
∑ Other Areas
Metal enclosure once every five (5) years
Fiber enclosure once every six (6) years
OVERHEAD LINE PATROLLING

information on the overhead network patrolling. Overhead network s, because of their
exposed nature, can very easily develop additional problems, apart from the normal
deterioration of network components. These include:
233

∑ Inadequate clearance over roads, over or near new.

∑ Buildings, trees and structures.
∑ Storm/lightning damage.
∑ Third party damage / interference.
The scheduling of the overhead line maintenance is based on the information recorded
on the patrol sheet. Likewise the materials, equipments and tools required to effect the
necessary repairs should be evident from the patrol sheet.
TYPES OF PATROLLING
Two types of periodic patrolling are carried out on the overhead distribution line
system, as follows:
Safety Patrol
This patrol is carried out to ensure safety to the public by the visual detection of
possible hazards. The patrol in open country, desert village and suburban area will be
conducted from a vehicle. In congested area, it will be sometime necessary to carry
out the patrol on foot.
Detailed Patrol
This patrol is carried out on foot along the route of a lin e in conjunction with planned
maintenance. The purpose of this patrol is to detect network defects and interference
prior to the start of planned maintenance on that section of line . Items to be covered in
this patrol are detailed in Fig. 4.1-25.
234

Fig. 4.1-25 Detailed Patrolling Sheet (cont'd)
235

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236

REVIEW EXERCISE
1. Match the left and right column shown below.
1. A padlocked A) The operation of any one fuse operating on a trip bar gives triple
hinged flap pole tripping of the switch fuse.
2. Interlock lever B) Restricts access to the operating shafts of the switches.
3. Striker pin fuses C) prevents the switch being operated through from ON to EARTH
4. Room substation. D) Supply LV network in residential and commercial areas.
5. Platform mounted E) The high tension is supplied to the transformer either by overhead
transformers lines or by underground cables from an RMU.
6. Dedicated s/s F) High tension is supplied to the transformer by U/G cable
7. Unit substations G) Installed outdoor to receive incoming cables from the LV panels
and outgoing cables for service connections.
8. Pad mounted H) Installed in consumer’s building, used for schools, apartment
transformer buildings, commercial buildings, industrial buildings and
compounds.
9. Mini-pillars I) For one customer.
2. Read the following statements then choose TRUE or FALSE
1. (SF6) is an inert, light gas having bad dielectric and arc extinguishing properties.
2. Same SF6 gas is recirculated in the circuit, hence the big requirement of SF 6 gas.
3. The maintenance required for RMU switch is minimum.
4. The life of metallic parts and contacts are longer in SF6 gas.
5. SF6 is a gas at low temperature and pressure.
6. Moisture has low effect to the properties of SF 6 gas.
7. The SF6 is a chemical inactive gas.
237

238

DEMONSTRATE DISTRIBUTION NETWORK

IN OUTSIDE YARD
TASK 4.1-1
IDENTIFY PRIMARY DISTRIBUTION EQUIPMENT
PROCEDURE
1. Study the following steps of the performance sheet , carefully.
2. Go to outside distribution equipment yard.
3. Identify and state the purpose of a distribution transfor mer.
4. Identify and state the purpose of distribution substation with pole mounted
transformers.
5. Identify and state the purpose of a distribution substation with platform
mounted transformers.
6. Identify and state the purpose of a distribution substation with pad mounted
transformer.
7. Identify and state the purpose of an indoor (consumer's type) primary
distribution substation. Go inside and point to Circuit Breaker and instruments
on switchgear.
8. Identify and state the purpose of a primary distribution overhead line.
9. Identify and state the purpose of a primary distribution underground cable
feeding an overhead line.
10. Identify and state purpose of a cable term .
239

TASK 4.1-2
IDENTIFY SECONDARY AND CUSTOMERS DISTRIBUTION
EQUIPMENT
PROCEDURE
1. Identify and state the pur pose of a secondary distribution transformer.
2. Identify and state the purpose of a LV panel.
3. Identify and state the purpose of metering instruments inside the LV panel.
4. Identify and state the purpose of incoming and outgoing cables for the LV panel.
5. Identify and state the purpose of a Mini -pillar.
6. Identify and state the purpose of incoming and outgoing cables for the Mini-
pillar.
7. Identify and state the purpose of a consumer's panel with KWH meters.
8. Identify and state the purpose of a consumer's panel with KWH meters and
Current Transformers.
240

LESSON 4.2
METER TYPES AND

CLASSIFICATIONS
241

242

LESSON 4.2
METER TYPES AND CLASSIFICATIONS
LESSON OVERVIEW
DESCRIPTION
This lesson overviews the operation and maintenance of different types of meters used
in power transmission and distribution systems.
OBJECTIVES
Upon completion of this lesson, the participants should be able to familiar ize with:
∑ Meter Types
∑ Meter Connections
∑ Meter Installation
∑ Whole Current (WC) Meter, Current and Voltage Transformer (CT & PT) Meter
243

244

INTRODUCTION
Electrical power is measured by Wattmeter. The electrical power is the rate at which
electrical energy is used and its unit of
measurement is the Watt while the unit of
measuring electrical energy is Watt-hour.
The instrument used to measure the electrical
energy is Watt-hour meter, which measures
the total electrical energy during specific
Fig. 4.2-1 Kilo-Watt-Hour Meter
time as kilo-Watt-hour meter. ( Fig. 4.2-1)
MEANS OF MEASURING ELECTRIC POWER

In alternating current circuits, power is the product of three quantities the potential
(Volts), the current (Amperes) and the Power Factor (%). Power is measured by a
Wattmeter as:
Active Power (P) = VI Cos F (Watts)
EXTENSION OF WATT -METER RANGE

The range of Wattmeter
Source H H To load
can be extended on AC 1 2
circuits by the use of H

H
2
PT
X1 CT X2
1 50/5
4800/120
instrument transformers
X
1 X 2
(PT & CT). A PT is
connected to the moving W
A
coil circuit. CT should V

4 Amperes
never be open circuit. Both

450 watts
112.5 Volts
the PT and CT multiplying
Fig. 4.2-2 Instrument Transformers (PT & CT)
factors must be applied to
the Wattmeter reading,
(Fig. 4.2-2).
245

Fig. 4.2-3 shows examples

of kilo-Watt meters and
Fig. 4.2-4 shows KW
meter connection s.
Fig. 4.2-3 Kilo-Watt Meters
Fig. 4.2-4 3-Wire/4-Wire Wattmeters
VAR METERS (Fig. 4.2-5)

In AC circuits that are not purely resistive, some power known as ( Reactive Power) is
delivered to the circuit during part of the cycle and returned to the source during
another part of the cycle. This reactive power does no useful work at the load but
increases the current in the circuit and results in
increased losses and poorer voltage regulation. VAR
meters measure the reactive power as the product of
voltage and current component , which is 90∞ out of phase
with the voltage.
Fig. 4.2-5 VAR Meter
246

It is common to have a condition where VARs are equal to the Watts. This is one
reason why overload occurs to feeders. Many substations have installed capacitors to
compensate for this condition.
WATT-HOUR METERS
The WH meter is an instrument that is used t o measure electrical energy. The (KWH)
meter is an instrument that is used to measure electric energy sold by SEC. Its function
is to provide an accurate record of the electric energy. KWH meters measure the
amount of electric energy passing through variou s parts of the generating, transmission
and distribution systems .
Some KWH meters are
equipped with demand
registers and named Watt-
hour demand meters. The
demand meters indicate or
record the peak demand or
the maximum demand at
given time period. Fig. Fig. 4.2-6 Maximum Demand KWH Meters
4.2-6 shows example of
maximum demand KWH
meters.
In principle, the Watt-hour meter is a small induction motor whose instantaneous

speed is proportional to the power passing through it. The total revolutions in a given
time are proportional to the total energy or Watt -hour consumed during that time, i.e.,
a Watt-hour meter will indicate 1000 Watt-hours if connected for two hours in a
circuit using 500 watt.
247

CONNECTED LOAD/DEMAND LOAD
CONNECTED LOAD: It is the combined rating of all the appliances or equipment

of the customer connected to the system.
DEMAND LOAD: It is the load demanded by the customer averaged over a suitable
and specified interval of time.
CLASSIFICATION OF METERS ACCORDING TO TYPE
METER TYPES
∑ WHOLE CURRENT (WC)
METERS
Used for low voltage
customer load not exceeding
150 Amps.
∑ CURRENT TRANSFORMER
(CT) METERS
Used for customer load
exceeding 150 Amps.
∑ CURRENT AND VOLTAGE

TRANSFORMERS (CT&PT)
METERS
Used for customer load from
Fig. 4.2-7 WC Metering Outdoor Arrangement
medium voltage 13.8 kV
and above.
STANDARD METER CONNECTIONS

Fig. 4.2-7 shows WC Metering Outdoor Arrangement.
248

Fig. 4.2-8 shows WC Metering

Connection Outdoor
Fig. 4.2-8 WC Metering Connection Outdoor
Fig. 4.2-9 shows LV

Metering Outdoor /Indoor
Arrangement up to 200
Amps.
Fig. 4.2-9 LV Metering Outdoor /Indoor
249

Fig. 4.2-10(a-b) shows meter box installation.
Fig. 4.2-10(a) Fig. 4.2-10(b)

Fig. 4.2-11(a-b) shows circuit breaker inside meter box.
Fig. 4.2-11(a) Fig. 4.2-11(b)
CT & PT CURRENT AND VOLTAGE TRANSFORMERS
Table 4.2-1 shows the Dimension of CTs, bus bar and cable size.
250

Table 4.2-1 CTs, bus bar and cable size
Fig. 4.2-12 shows LV CT metering connection.
Fig. 4.2-12 LV CT metering Connection
251

MEDIUM VOLTAGE KWH METER WITH CURRENT AND

VOLTAGE TRANSFORMERS
Fig. 4.2-13 shows MV metering installation 3-wire systems 3-phase, 3-wire, 2 element,
CT, PT operated KWHM.
Fig. 4.2-13 MV metering Installation
252

Fig. 4.2-14 shows CT/PT metering arrangement incorporated in bulk supply MV

Circuit Breaker.
Fig. 4.2-14 CT/PT metering in Bulk Supply MV Circuit Breaker
INSTALLATION OF KWH METERS INSIDE

METER ROOMS AND INSETS
The standard specifies the design of meter room and method of installatio n of KWH
meters inside the meter rooms and building insets. It is intended to assist the field
engineers and technicians to achieve uniform standard in construction to ensure a
satisfactory and economical level of service without operating restrictions so that the
operational errors are minimized for safety and reliability of the system.
METHOD OF METER INSTALLATION

1. Mainly the quadruple meter box (Four meter boxes) shall be used for any group
installation.
2. Single, double, CT and remote meter boxes shall be used in conjunction with
four meter boxes to complete the installation as per plan.
3. A space of 10 mm shall be provided between two adjacent meter boxes
installed side by side as shown in the attached figures.
253

METERS IN INSETS
∑ As per standard one to four meters can be installed on the front wall of the
consumer.
∑ For the installation of 4 to 16 meters, the consumer shall provide a wall in an
inset to install the meters.
∑ Meters in the inset shall be installed in meter boxes as per prototype depending
on the number of meters in the plan , (Fig. 4.2-15, 16, 17, 18, 19).
∑ A space of 10 mm shall be provided between two adjacent meter boxes .
∑ A clearance of 200 mm shall be maintained between the meter boxes and the
border of the assigned area on the right, left and th e top of the installation.
∑ Clearance between the bottom of any meter box and the ground level shall be
800mm.
Fig. 4.2-15 Meter Box Installation in Inset
254

255

256

METER INSPECTION AND MAINTENANCE

information on the planned Inspection and Maintenance of MV/LV Meter
Installations. Meter Installations are required to be maintained regularly in order to
keep the meter installations up to SEC Standards to eliminate any potential hazards
present and to protect SEC from the losses incurred by meter errors developed after a
certain period of service .
SAFETY PRECAUTIONS
∑ Ensure that approved personal protective equipment is used.
∑ Ensure that required work clearances (work permit and hold tags) have been
obtained.
MAINTENANCE OF METER INSTALLATIONS

When a problem is discovered at an LV metering installation, in order to restore
supply quickly and minimize customer inconvenience, the shift electricians usually
restore power supply bypassing the faulted equipment temporarily. For MV metering
installations, problems are handled by Network Operators and Meter Maintenance
might be called out, if necessary. Observations/Remarks and temporary repair
requiring follow-up action shall be forwarded to the Unit/Segment responsible for
Meter Maintenance.
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258

REVIEW EXERCISE
1-Complete the following
Classify the meters according to type of current to be measured:
a) --------------------------------- (WC) METERS
Used for low voltage customer load not exceeding 150 Amps.
b) ------------------------------------- (CT) METERS
Used for customer load exceeding 150 Amps.
c) --------------------------------------------------------------- (CT&PT) METERS
d) Used for customer load from medium voltage 13.8 kV and above.
2-Match the left and right column shown below.

1. Use of instrument A. The rate at which electrical energy is used
transformers
2. The electrical power B. Extend the range of Wattmeter on AC circuits
3. The three-phase C. Is never open-circuited.
Wattmeter
4. VAR meters D. To measure three-phase power
5. Two single phase E. Measure the product of voltage and current
Wattmeters component, which is 90∞ out of phase with the
voltage.
6. Current transformer F. Is a combination of single phase Wattmeter elements
that drive a shaft at a speed proportional to the total
power in the circuit
259

260

UNIT-5
ELECTRICAL DIAGRAMS,
SWITCHING ACTIVITIES,
LINEMAN AND CABLEMAN
261

262

UNIT-5
ELECTRICAL DIAGRAMS, SWITCHING ACTIVITIES,
UNIT OVERVIEW
DESCRIPTION
This unit consists of four lessons:
Lesson 5.1 familiarizes the participants with different types of Electrical Drawings
used for maintenance and troubleshooting of electrical power systems. This lesson
describes the layout and single line electrical diagrams.
Lesson 5.2 familiarizes the participants with Switching Activities of electrical
systems. The switching activities include switching to transfer load, switching to
energize isolated circuits, switching apparatus with remote operation facilities as well
as hold tags and lockout, grounding and safety procedures.
Lesson 5.3 for Lineman and Cableman Activities, discusses how the lineman in SEC
maintains and constructs OH Distribution and Transmission lines and be
knowledgeable of materials, work procedures and safety precautions necessary to
perform his job. The cableman's duties include the quality of joint and termination
while using manufacturer instructions for installation , making precise measurements
and cleaning joints by properly applying heat to shrinkable materials.
In Lesson 5.4 for Cable Splicing Activities, mainly Cable Receiving, Safety Aspects,
Work Procedures, Work Site Preparation, Direct Burial of Cable in the Ground and
Trenches, Cable Preparation, Joint and Termination, Pre-Commissioning Tests,
Ground Testing by Megger, Continuity Tests and Phase Rotation Tests are discussed.
263

OBJECTIVES
Upon completion of this unit the participants should be able to familiarize with :
∑ Layout and single line electrical diagrams.
∑ Block diagrams.
∑ Schematic diagrams.
∑ Switching to transfer load.
∑ Switching to energize isolated circuits.
∑ Switching apparatus with remote operation facilities.
∑ Hold tag and lockout procedures.
∑ Grounding and safety procedures.
∑ Transmission and Distribution Lineman Duties .
Hazards, Materials, Equipment and Tools Identification, Work Procedures and
Safety Precautions
∑ Transmission and Distribution Cableman Duties .
Cable Receiving, Safety Aspects and Work Procedures, Work Site Preparation,
Direct Burial of Cable in the Ground and Trenches Cable Preparation, Joint and
Termination
∑ Cable Splicing
∑ Pre-Commissioning Tests
Ground Testing by Megger, Continuity Tests, Phase Rotation Tests
264

LESSON 5.1
ELECTRICAL DIAGRAMS
265

266

LESSON 5.1
ELECTRICAL DIAGRAMS
LESSON OVERVIEW
DESCRIPTION
This lesson describes the layout and single line electrical diagrams, including Block
diagrams and Schematic diagrams.
OBJECTIVES
Upon completion of this lesson, the participants should be familiarized with:

∑ Layout and single line electrical diagrams .
∑ Block diagrams
∑ Schema tic diagrams
Task 5.1-1: Isolating Power Transformer (T -703) 230 /69 kV
267

268

INTRODUCTION
Before we read and correctly interpret the electrical diagrams, we will define the
different types of the electrical diagrams as follows:
∑ Block diagrams represent all electrical network equipment as blocks to show
power flow.
∑ Single line or one line diagrams are shown by single lines and graphic symbols.
∑ Schematic diagrams are the basic reference for control circuits and electricians
use them to understand the operation of control circuits. Schematic diagrams are
made of standard symbols, function numbers and lines.
BLOCK DIAGRAMS
Block Diagrams represent all electrical equipment as rectangular functional blocks
with text interconnected by arrowed lines, the arrows indicating the signal flow.
They do not use standard symbols or abbreviations. The purpose of the block
diagrams is to:
∑ Show the flow of power through a system/equipment in one or more stages
of functional blocks.
∑ Understand the system operation.
For example, Fig.

5.1-1 shows the
block diagram for
Uninterruptible
Power Supply (UPS).
Fig. 5.1-1 Block Diagram of Uninterruptible Power Supply

(UPS)
As the system equipment gets complicated, its drawing gets simpler. This is because
it will be drawn as stage-by-stage block diagram. In troubleshooting, the electrician
will just measure and compare the output of each stage. Any faults may exist where
it deviates from normal.
269

SINGLE LINE DIAGRAMS

∑ Single line diagrams
are simplified
representations of
complex circuits or
entire systems. The
single line or one
line diagram (Fig.
5.1-2) is the most
basic diagram used
in electrical power
industry, because it
is actually a "short
hand" method of
representing most
complex power
Fig. 5.1-2 Single Line Diagram for Unit Distribution Substation
system. The single
line diagram may be
used in a very
general and
abbreviated manner to illustrate broad system ideas or in a very detailed manner to
illustrate all of the components in a particular par t of the system.
∑ Single line diagrams show circuits as single lines irrespective of the actual number
of conductors or phases in it. It uses standard symbols and abbreviations. Their
purpose is to give a pictorial overview of an electrical system.
∑ Single line diagrams are used primarily in the electrical power and control areas.
∑ The single line diagram does not represent actual wiring, but only indicates that
some kind of connection exists between components.
∑ Typically, single line diagrams are used to show how power is distributed to various
loads in a facility. This information is useful when determining how to isolate a
part of the system for maintenance.
270

As shown in Fig. 5.1-2, single line diagrams can also be used to show how meters
(Ammeters/Voltmeters) or protective devices (fuses) are connected to the system.
Along with identifying the components of the system, single line diagrams usually
include additional information, such as:
1. The major components, switching devices and connecting circuits in a sys tem.
2. Ratings of the major components (Ring Switches, 400 A).
3. Voltage level at various points in the circuit (13.8-231/133 kV).
4. Control functions provided in the circuit.
5. The path or power flow in a plant or a system.
6. The specifications and types of each equipment used (voltage level, CB
rating, transformer capacity, vector group etc)
This information is useful to:

1) Understand system, generally. 2) Decide how to isolate a part of a system
for maintenance.
∑ In some single line diagrams with
three slashes are drawn on a single
line, the three slashes on single
line representing three conductors
per phase, as shown in Fig. 5.1-3.
∑ The single line diagram is read by
starting from a point nearest to the
power supply and following the
line through the entire diagram.
This method is useful in locating
the correct circuit breaker to
isolate a component for Fig. 5.1-3 Three Conductors/Phase, single
maintenance. line diagrams
THREE LINE DIAGRAMS

It is an expansion of the single line diagram. Its primary purpose is to illustrate
graphically the electrical connections and functions of the metering and power
271

control circuitry. It doesn't show the control of power equipment. These diagrams
are usually done for substations. Fig. 5.1-4(a) shows three line diagrams for a LV
distribution cabinet. It shows the details of:
∑ Voltmeter and Ammeter connections .
∑ Protective devices (fuses).
∑ Instrument Transformers (CTs) .
Fig. 5.1-4(b) also shows an example of three line diagrams.
Fig. 5.1-4 Three Line Diagrams
SCHEMATIC DIAGRAMS
Schematic diagram in Fig. 5.1-5, also called "Elementary Diagrams", like the other
electrical diagrams, are made of symbols and lines.
Fig. 5.1-5 Schematic Diagram of Power Circuit for 3φ Motor
272

A schematic diagram (often called schematic) shows all the components in a circuit
and how each component is electrically connected, but not necessarily in their
proper physical locations. It also shows how the circuit is designed to operate. Fig.
5.1-5 is the "power circuit" of a "motor control circuit", identifying the components
in the circuits as follows:
1. Motor 2. Circuit breakers 3. Starter contactors (Magnetic starter)
4. Fuses 5. Overload protection 6. Magnetic protection (short circuits)
The dotted line at the circuit breaker indicates that the 3 breaking mechanism are
ganged and they move together.
∑ The symbols represent the power source, components and the devices of the
circuits.
∑ The function numbers and abbreviations represent type of switch, relay or device.
∑ The lines represent the conductors connecting the devices.
Schematics are usually designed to be read from left to right and from top to bottom.
They typically use standard electrical diagram symbols and device function
numbers. The position of the contacts and switches are shown as they would be in
the de-energized state.
The electrician should determine the following conditions from the catalog or from
the notes on the drawing :
∑ The initial conditions at which the diagram is drawn.
∑ The normal conditions at which the system will operate.
∑ The stop/trip con ditions.
EXAMPLE 5.1-1
In the single line diagram for electrical network in Fig. 5.1-6:
∑ Unit 1 feeds bus bar A ∑ Unit 2 feeds bus bar B
∑ Unit 3 feeds bus bar C ∑ Unit 4 feeds bus bar D
∑ Bus Tie 1 disconnected ∑ Bus Tie 2 disconnected
∑ Bus coupler 1 connected ∑ Bus coupler 2 connected
a) What is the load of transformers T 1 and T2?
273

b) What is the load of transformers T 1 and T2 if Bus Tie 1 is connected?

c) If Bus Tie 1 is connected and the feeder F6 disconnected, what is the load of T1
and T2?
d) If Bus Tie 1 is connected and the unit 1 is tripped, what is the load of T 1 and T2?
Fig. 5.1-6 Single Line Diagram for electrical Network
SOLUTION
a) The electrical network is divided into two sections (left and right) because bus tie
1 & 2 are disconnected .
Left Section U1 + U2 = 60 + 60 = 120 MW
F1 + F2 + F3 = 40 +50 + 50 = 140 MW
The generated MW from U1 and U2 is not enough (20 MW lost) to feed
the feeders F1, F2 and F3
Transformer T1 will receive 20 MW from 230 kV network to balance the
network.
Right Section U3 + U4 = 60 + 60 = 120 MW
F4 + F5 + F6 = 50 + 50+ 10 = 110 MW
The generated MW from U3 and U4 is more than required (10 MW
more) for feeders F1, F2 and F3.
Transformer T2 will send 10 MW from 69 kV network to 230 kV
network to balance the network.
274

b) If Bus Tie 1 is connec ted, all the network connected together (no sections) and the
transformers T1 and T2 will divide their loads together .
U1 + U2 + U3 +U4 = 60 + 60 + 60 + 60 = 240 MW
F1 + F2 + F3 + F4 + F5 + F6 = 40 +50 + 50 + 50 + 50 +10 = 250 MW
The generated MW from U1, U2, U3 and U4 is not enough (10 MW lost) to feed
the feeders F1, F2, F3, F4, F5 and F6.
So, Transformers T1& T2 will divide their load and receive 5 MW for each from
230 kV network to balance the network.
c) If Bus Tie 1 is connected and the feeder F 6 disconnected:

U1 + U2 + U3 +U4 = 60 + 60 + 60 + 60 = 240 MW
F1 + F2 + F3 + F4 + F5 = 40 +50 + 50 + 50 + 50 = 240 MW
Each Transformer (T1 and T2) will load zero MW.
d) If Bus Tie 1 is connected and the unit 1 is tripped:

U2 + U3 +U4 = 60 + 60 + 60 = 180 MW
F1 + F2 + F3 + F4 + F5 + F6 = 40 +50 + 50 + 50 + 50 +10 = 250 MW
The generated MW from U2, U3 and U4 is not enough (70 MW lost) to feed the
feeders F1, F2, F3, F4, F5 and F6.
230 kV network to make balance in the network.
SUMMARY
∑ Block diagrams represent all electrical network equipment as blocks to show
power flow.
∑ Single line or one line diagrams are shown by single lines and graphic symbols.
∑ Schematic diagrams are the basic reference for control circuits and electricians
use them to understand the operation of control circuits.
∑ Schematic diagrams are made of standard symbols, function numbers,
abbreviations and lines.
GLOSSARY
UPS: Uninterruptible Power Supply LV: Low Voltage
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276

REVIEW EXERCISE
1. The block diagrams with symbols facilitate troubleshooting be measuring input
and output signals.
a) True b) False
2. The ________________ diagram may be used in a very general and abbreviated

manner to illustrate broad system ideas or in a very detailed manner to illustrate
all of the components in a particular part of the system.
3. ______________ diagrams for a LV distribution cabinet shows the details of:

a) Voltmeter and Ammeter connections
b) Protection (fuses)
c) Instrument Transformers (CTs)
4. __________diagrams are very useful to troubleshoot power control circuits.
5. In the single line diagram for electrical network in Fig. 5.1-7:

b) What is your action if transformer T 1 tripped (solution two )?
c) What is the load of transformers T 1 and T3 if Bus Tie 1 is connected?
d) If Bus Tie 1 is connected and the feeder F2 disconnected, what is the load of
T1 and T3?
e) If Bus Tie 1 is connected and unit 1 is tripped, what is the load of T 1 and T3?
Fig. 5.1-7
277

278

TASK 5.1-1
ISOLATING POWER TRANSFORMER (T-703) 230 /69 kV
OBJECTIVES
1. Practice and follow switching procedures.
2. Practice and follow grounding procedures.
3. Write switching rep orts.

1 - Network operation simulator
SAFETY PRECAUTIONS
1. Wear required safety equipment .
2. Follow the trainer's directions.
PROCEDURE
1. Study steps of the performance sheet.
2. Receive from your instructor single line diagram for transformer in Fig. 5.1-8
& 5.1-9.
3. Check transformer (T-703) that must be isolated for repair .
4. Check transformers (T-701), (T-702) in normal service.
5. 69 kV oil CB A 524 (refer to the single line diagram attached) must be opened
and tagged.
6. 230 kV SF6 (A703) for transformer (T-703) must be opened and tagged .
7. Disconnect switch (D707) must be in open position and tagged .
8. Disconnect switch (D708) must be in open position and tagged .
9. Disconnect switch (809) must be in open position and tagged.
10. PT on 230 kV side, secondary coil must be opened and tagged.
11. Disconnect (D548) must be in open position .
279

12. Disconnect (D547) must be opened and tagged .

13. PT "on 69 kV side" secondary coil must be opened and tagged.
14. Ground switch (K 528) must be closed for transformer (T-703) and tagged.
15. Ground switch (K711) must be closed and tagged .
Fig . 5.1-8 69 kV Side
280

Fig. 5.1 -9 230 kV Side
NOTE
Now transformer (T -703 ) is isolated and ready for repair .
281

282

LESSON 5.2
SWITCHING ACTIVITIES
283

284

LESSON 5.2
SWITCHING ACTIVITIES
LESSON OVERVIEW
DESCRIPTION
This lesson explains the switching activities including switching to transfer load,
switching to energize isolated circuits, switching apparatus with remote operation
facilities as well as hold tag and lockout , grounding and safety procedures.
OBJECTIVES
Upon completion of this lesson, the parti cipants should be familiar ized with:
∑ Switching to transfer load.
∑ Switching to energize isolated circuits.
∑ Switching apparatus with remote operation facilities.
∑ Hold tag and lockout procedures.
∑ Grounding and safety procedures.
Task 5.2-1: Energizing Power Transformer (T -703) 230 /69 kV
285

286

INTRODUCTION
Switching activities are the responsibility of the network operator with coordination
of the power dispatcher to isolate or energize a piece of electric equipment safely
whenever maintenance or repair is required or completed after fault removal.
SWITCHING PROCEDURE
a. All transmitted switching orders used in conn ection with switching at a station
shall be written in an approved form, as shown in Table 5.2-1.
b. When issuing switching orders, the power dispatcher shall state in detail and in
proper sequence the switching to be performed and shall require the person
taking the order to repeat the order word for word.
c. Network Operator shall not execute more than steps of a switching operation
than has been ordered by the dispatcher.
d. All switching shall be performed by an authorized person and in detail and
seque nce as ordered by the issuing dispatcher.
e. If for any reason the Network Operator is delayed in executing a switching
order, he shall not perform the order but contact power dispatch control
center, which issued the order for instructions.
Table 5.2-1 Switching Order Form
287

The order in which a switching program is carried out to isolate circuits, line or
equipment should be , as shown in Table 5.2-2:
Table 5.2-2 Order of switching Power System

1. SWITCH Open the breakers to remove the load from the circu it or
equipment.
2. ISOLATE By opening the disconnects or racking out the breakers
to give "visible open points" at all possible sources of
feed to the area of isolation.
3. TAG AND LOCK Tag and lock each point of isolation.
4. TEST All tests are carried out by operations using an approved
tester following the instructions in testing procedures.
5. ISSUE Explain to the craftsman accepting the clearance the
CLEARANCE BY
limitation of his access, the safe work area, the points of
NUMBER
isolation and precautions necessary. At the time of
issuing the clearance, order the craftsman to test for
potential as required and order working grounds applied.
SWITCHING TO TRANSFER LOAD

The following steps should be carried out when it is necessary to transfer load to
an alternative source or tie line:
1. Check that feeds are synchronized i.e., the primary sources are tied together
through either the transmission or distribution system in such a way that the
frequency and phase angle are identical.
2. Check that the a lternative feed is capable of accepting the additional load.
3. Match the voltage between the two sources and set the tap changers in the
manual mode where automatic tap changes are in use.
4. Close the open point between the two circuits by closing the breaker or
disconnect switch.
5. Move the open point to the desired location by opening the breaker or load
break disconnect wherever possible.
288

6. Adjust the voltage at the original locations and set the tap changers to
automatic that was previously set to t he manual mode.
7. Check the load at both sources to confirm that the original forecast of load
transfer is correct.
SWITCHING TO ENERGIZE PREVIOUSLY ISOLATED CIRCUITS

The following steps should be followed to energize a circuit or equipment
previously iso lated or under a clearance for work to be performed:
1. Craftsman releases his clearances and/or permits to Power Dispatcher.
2. Operations check and confirm that no other clearances remain in effect.
3. Craftsman confirms that work is completed and all personnel and grounds
applied by the craftsman are clear.
4. Operators confirm that the work site is safe to energize and that the apparatus
is in the same operating position as before the clearance was issued, unless
otherwise stated.
5. Follow the agreed switching program to energize the line(s) and equipment
removing all signed -off Hold Tags even at locations where switching may not
be necessary.
6. Operators check and confirm that all Hold Tags listed on the switching
program have been returned.
SWITCHING EQUIPMENT WITH REMOTE OPERATION FACILITY

Switching carried out on equipment with a LOCAL/REMOTE facility will be
operated from the REMOTE location unless this mode is inoperable and then
only after consultation with the Power Dispatcher. After local operation is
completed, return LOCAL/REMOTE switch to REMOTE position unless it
remains inoperable. If inoperable, report it to the correct group for prompt
repairs.
HOLD TAG AND LOCKOUT PROCEDURES

After the switching operation has been performed, the Network Operator shall,
whenever possible, lockout the controller and/or attach Hold Tags, as required .
289

The purpose of Lockouts and Hold Tags is to make sure that the controller
remains open while work is being done on any system and to protect the
personnel workin g on the portion of the system being protected by the controller.
GROUNDING
A ground system consists of grounding conductors connected together at all times
to ground electrode contacts. The electrode makes contact with the earth and
consists of buried conductors and ground wells with certain specifications. The
grounding systems serve four main functions:
1. To safeguard a person from electric shock under fault conditions; all surfaces
remain at safe condition contacting the ground.
2. To safeguard electri cal equipment
by grounding power systems.3.
To provide a path to ground from
lightning arresters that may operate
under conditions of direct lightning
strike, surges induced by lightning
or switching surges.
4. To reduce the possibility of static
discharge and hence fire risk for
grounding performed by earthing
switches and connected at definite
Fig. 5.2-1 Earthing Switches connected
points on the circuit, as shown in at definite Points on Circuit
Fig. 5.2 -1.
When high-voltage equipment is to be discharged and grounded, it is done by a
special ground switch or approved device to make ground connection. Where this is
not possible, the high -voltage equipment may be discharged by a working ground lead
applied by an approved device.
No high-voltage ground switch will be closed to the transmission or distribution
system unless it is part of an approved switching operation and is approved by the
Power Dispatcher or after the switching program has been approved by the Network
Foreman/Supervisor.
290

EXAMPLE 5.2-1
In the single line diagram for electrical network in Fig. 5.2-2
∑ Unit 1 feeds bus bar A ∑ Unit 2 feeds bus bar B
∑ Unit 3 feeds bus bar C ∑ Unit 4 feeds bus bar D
∑ Bus Tie 1 disconnected ∑ Bus Tie 2 disconnected
∑ Bus coupler 1 connected ∑ Bus coupler 2 connected
b) What is the load of transformers T 1 and T2 if Bus Tie 1 is connected ?
c) If Bus Tie 1 is connected and the feeder F 6 disconnected , what is the load of T 1
and T2?
d) If Bus Tie 1 is connected and the unit 1 is tripped, what is the load of T 1 and
T2?
Fig. 5.2-2 Single Line Diagram for Electrical Network
291

SOLUTION
a) The electrical network is divided into two sections ( left and right) because bus tie
1 & 2 are disconnected .
U1 + U2 = 60 + 60 = 120 MW
Left section F1 + F2 + F3 = 40 +50 + 50 = 140 MW
The generated MW from U 1 and U2 is not enough (20 MW lost)
to feed the feeders F 1, F2 and F3
Transformer T 1 will receive 20 MW from 230 kV network to
balance the network.
U3 + U4 = 60 + 60 = 120 MW
Right section F4 + F5 + F6 = 50 + 50+ 10 = 110 MW
The generated MW from U 3 and U4 is more than required (10
MW more) for feeders F1, F2 and F3
Transformer T 2 will send 10 MW from 69 kV network to 230 kV
network to balance the network.
b) If bus tie 1 is connected to all network connected together (no sections) and the
transformers T1 and T2 will divide their loads together :
U1 + U2 + U3 +U4 = 60 + 60 + 60 + 60 = 240 MW
F1 + F2 + F3 + F4 + F5 + F6 = 40 +50 + 50 + 50 + 50 +10 = 250 MW
The generated MW from U1, U2, U3 and U4 is not enough (10 MW lost) to feed
the feeders F1, F2, F3, F4, F5 and F6.
230 kV network to balance the network.
c) If Bus Tie 1 is connected and the feeder F 6 disconnected :

U1 + U2 + U3 +U4 = 60 + 60 + 60 + 60 = 240 MW
F1 + F2 + F3 + F4 + F5 = 40 +50 + 50 + 50 + 50 = 240 MW
Each Transformer (T1 and T2) will load zero MW.
d) If Bus Tie 1 is connected and the unit 1 is tripped:
U2 + U3 +U4 = 60 + 60 + 60 = 180 MW
F1 + F2 + F3 + F4 + F5 + F6 = 40 +50 + 50 + 50 + 50 +10 = 250 MW
The generated MW from U2, U3 and U4 is not enough (70 MW lost) to feed the
feeders F1, F2, F3, F4, F5 and F6.
Transformers T1& T2 will divide their load and receive 35 MW for each from
230 kV network to make balance in the network.
292

SUMMARY
∑ Switching activities are the responsibility of the network operator with
coordination of the power dispatcher.
∑ When issuing switching orders, the power dispatcher shall state in detail and in
proper sequence the switching to be performed and shall require the person
taking the order to repeat the order word for word.
∑ Network Operator shall not execute more than steps of a switching operation
than has been ordered by the dispatcher.
∑ A ground system consists of grounding conduc tors connected together at all
times to ground electrode contacts.
∑ No high-voltage ground switch will be closed to the transmission or distribution
system unless it is part of an approved switching operation and is approved by the
Power Dispatcher or after the switching program has been approved by the
Network Foreman/Supervisor .
GLOSSARY
kV: Kilo-Volt kW: Kilo-Watt
T: Transformer
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294

REVIEW EXERCISE
1. Switching purpose is to ________ or __________ a piece of electric equipment
safely whenever ______________ or __________ is required or completed after
fault removal.
2. All switching shall be performed by an authorized person and in detail and

sequence as ordered by the issuing dispatcher.
a) True b) False
3. List the five orderly steps in which a switching program is carried out to
isolate circuits, line or equipment.
a) ------------ b) ------------ c) ------------- d) ------------- e) ------------
4. The purpose of Lockouts and Hold Tags is to make sure that the controller
remains open while work is being done on any system and to protect the
personnel working on the portion of the system being protected by the
controller.
a) True b) False
5. In the single line diagram for electrical network in Fig. 5.2-3:

b) What is your action if transformer T 1 tripped (solution two )?
c) What is the load of transformers T 1 and T3 if Bus Tie 1 is connected ?
d) If Bus Tie 1 is connected and the feeder F 2 disconnected , what is the load of T 1
and T3?
e) If Bus Tie 1 is connected and unit 1 is tripped, what is the load of T 1 and T3?
295

Fig. 5.2-3 Single Line Diagram for Electrical Network
296

TASK 5.2-1
ENERGIZING POWER TRANSFORMER (T-703) 230 /69 kV
OBJECTIVES
1. Practice and follow switching procedures.
2. Practice and follow grounding procedures.
3. Write switching reports.

1 - Network operation simulator
SAFETY PRECAUTIONS
∑ Wear required safety equipment
∑ Follow the trainer's directions.
PROCEDURE
1. Study steps of the performance sheet.
2. Receive from your instructor single line diagram for transformer, Fig. 5.2-4 and
5.2-5.
3. Ground switch (K711) for transformer (T 703 ) must be opened and tag
removed.
4. Ground switch (K528) for transformer (T 703 ) must be opened and tag
removed.
5. PT (on 69kV side ) secondary coil must be closed and tag removed .
6. PT (on 230 kV side ) secondary coil must be closed and tag removed .
7. OCB (A524 ) must be checked open .
8. Disconnect (D548) must be opened .
9. Disconnect (D547 ) must be closed and tag removed.
10. GCB (A703 ) and Disconnect (D707 ) must be checked open .
11. Disconnect (D709 ) and Disconnect (D707) must be checked open .
297

12. Disconnect (708 ) must be closed and tag removed .

13. GCB (A703 ) on 230 kV side must be closed and tag removed .
14. OCB (A524) for (T 703 ) must be racked in and closed .
15. All transformers must be checked for normal loading.
16. All tags must be returned.
Fig . 5.2-4 69 kV Side
298

Fig. 5.2 -5 230 kV Side
299

300

LESSON 5.3

ACTIVITIES
301

302

LESSON 5.3
LINEMAN AND CABLEMAN ACTIVITIES
LESSON OVERVIEW
DESCRIPTION
In this lesson, Lineman Craft Pole and Tower (Materials, Equipment and Tools),
Work Safety Precautions and Procedures, OH Distribution Lines (13.8 kV and 34.5
kV) OH, Transmission Lines (69 kV, 115 kV, 230 kV and 380 kV), Steel Towers and
Hazards of Lineman Craft and Safety Equipment and Hot Sticks are discussed.
OBJECTIVES
Upon completion of this lesson, the participants will be familiarized with:

∑ Lineman Craft Pole and T ower (Materials, Equipment and Tools)
∑ Identification Work Procedures and Safety Precautions
∑ OH Distribution Lines (13.8 kV and 34.5 kV) OH
∑ Transmission Lines (69 kV, 115 kV, 230 kV and 380 kV) Steel Towers
∑ Hazards of Lineman Craft and Safety Equipment Hot Sticks
303

304

INTRODUCTION
A lineman in SEC maintains and constructs OH Distribution and Transmission lines.
His duties require him to work on poles and towers as well as on ground surfaces.
Beside pole and tower climbing skills, the lineman must be knowledgeab le of rigging
and lifting techniques, materials, work procedures and safety precautions necessary
for performing a job. A lineman uses specialized tools and equipment in his daily
activities and follows specific procedures to handle SEC standard tools and materials.
STANDARD POLES, TOWERS AND SWITCH YARD STRUCTURES

Steel poles and steel towers are used for carrying conductors between power sending
and receiving ends in both distribution and transmission networks. Steel poles are
widely used for OH distribution lines (LV, 13.8kV and 34.5kV) and in OH
transmission lines (69kV, and 115kV). Steel towers are used for transmission lines
(69, 115, 230, 380kV). In some cases, steel poles are carrying some of the
distribution line equipment, such as Transformers, Fuse Cutouts, Voltage
Regulators.
Switchyards are the places where a transmission line terminates into buses as
outgoing or incoming lines or equipment bushing. The following figures show
examples of poles and transmission tower structures, as shown in Fig. 5.3-1 and Fig.
5.3-2.
305

Fig. 5.3-1 Poles and Transmission Tower Structures
306

Fig. 5.3-2 Poles and Transmission Towers Structures
LIFTING AND RIGGING

The lineman rigs, lifts and fits in place heavy weight (tons in transmission) equipment
on pole/tower top . The lineman can achieve this by being skilled in rigging and lifting
techniques, proper use of rope and pulleys, tension machines and appropriate tools,
etc. Also, the lineman must be fully familiar with the use of the lifting cranes and
limitations of their use. The lineman installs scaffolds, ladders and platforms on tower
tops. The following Fig. 5.3-3, Fig. 5.3-4 and Fig. 5.3-5 show some operations
involving rigging and lifting as integrated steps of these operations. It is a safety
hazard to use a rope or lifting equipment of less tensile strength than weight of the
load.
307

Fig. 5.3-3 Rigging and Lifting
308

Fig. 5.3-4 Rigging and Lifting Fig. 5.3-5 Rigging and Lifting
HAZARDS OF LINEMAN CRAFT

Usually, the lineman reaches the pole/tower top by usi ng a bucket truck, but when this
equipment is not available for some reason, the lineman climbs up to the position of
work. The job of a lineman carries a considerable element of risk. This element of risk
can be greatly decreased by knowing the source of these hazards. The following items
indicate hazard sources that can be eliminated simply by adherence to proper safety on
the job:
1. Following correct procedure of receiving de-

energized line.
2. Pole conditions (inclined, cracks, rotten, etc)
3. Fixture on the pole (nails, danger signs, wires,
etc)
4. Clothes (long sleeve shirts, proper climbing boat,
clean work gloves, proper sizes, etc)
5. Climbing practices (hurrying up or down,
overconfidence, bringing the knees close to the
poles, etc)
6. Climbing saddle and gaff are not safe, waist belt,
safety strap are worn out.
Fig. 5.3-6 Lineman constructing Steel
Fig. 5.3-6 shows a lineman constructing a steel Tower
tower
309

Fig. 5.3-7 and 8 show climbing and safety equipment .
Fig. 5.3-7 Climbing and Safety Equipment
310

Fig. 5.3-8 Climbing and Safety Equipment
LINEMAN RECEIVING DE-ENERGIZED LINE

A lineman crew works directly on lines and equipment 0NLY when it is de-
energized. A lineman before starting any work must check for presence of voltage on
a de-energized line (induction effect from near parallel lines) and install temporary
ground before starting any work directly on de-energized line for equipment.
Hot sticks, as shown in Fig. 5.3-9, are used for checking voltage by a MV buzzer
tester and to install temporary ground. It is an important safety aspect to install
temporary ground first to a buried ground rod, then to the line and when removing
temporary ground, a reversed sequence of de-installation is followed.
311

Fig. 5.3-9 Hot Stick Operation
LINE EQUIPMENT
Besides conductors, insulators, guy wires (to support poles against conductor
tension) hardware bolts, nuts, brackets, poles and tower structures, OH distribution
poles can be used for mounting Pole Mounted Transformers (PMT), current and
potential transformers, CTs and PTs, voltage regulator, capacitors, disconnects and
air load breaks, OH Transmission line insulators, lightning arrestors, buses,
bushings in switchyards etc. The Fig. 5.3-10 shows CTs and PTs mounted on an
MV metering pole as examples of this equipment.
312

Fig. 5.3-10 CTs and PTs mounted on MV Metering Pole
Fig. 5.3-11 shows a Pole Mounted Transformers (PMT) , which are used to supply LV
network in OH line areas. In this type of substation, the high tension is supplied to the
transformers by overhead lines. Fig. 5.3-12 shows Platform Mounted Transformers.
Here the high tension is supplied to the transformer either by overhead lines or by
underground cables through a pad mounted Ring Main Unit (RMU).
313

Fig. 5.3-11 PMT Fig. 5.3-12 RMU
MV AIR SWITCHES AND ISOLATORS

Air switches are an essential element of electrical distribution system. A switch is a
device for making, breaking, or changing connections in an electric circuit under the
rated load conditions.
Air switches are divided into two general class es:

Air Break Switches: Light-load line interrupters
Disconnect Switches: No-load line openers
The primary purpose for each class is to isolate equipment for maintenance.
AIR SWITCHES
All air switches are either air break or disconnect devices and are helpful in opening
unloaded circuits. All air switches are mounted on insulators that are parts of the
switch. The higher the rated voltage, taller is the stack of insulators. Either class of air
switches is often installed on both sides of a transformer or other substation
equipment, primarily to isolate the equipment for maintenance. Any of these switches
can be used as single phase modules or set up as GANG OPERATED three-phase
units, as shown in Fig. 5.3-13.
314

Fig. 5.3-13 Gang operated Three Phase Air Switch
Although air switches can often be hot stick operated, they are frequently opened and
closed by an operating rod mounted on the structure. These switches are usually pole
mounted, but are also frequently mounted on steel or wooden substation structures
called racks.
Air switches provide positive, visible air gap isolation of equipment and line sections
for safe examination, maintenance and repair. In the closed position, air switches must
provide adequate capacity to handle all normal and abnormal curre nts, which flow in
the system. Most air switches are installed only for local manual operation.
Some switches open and close by vertical action but others operate by rotation in a
horizontal plane. The way and procedure of operation of air switches is a very
important part of the operation, maintenance and switching of substation equipment.
An air-break switch can open a circuit when only light current is flowing. The
airbrake switch will break the ARC in air by drawing the arc out until it is quenched ,
as shown in Fig. 5.3-14 .
315

Fig. 5.3-14 Arc Chute for Arc Quencher Fig. 5.3-15 Arching Horns
The air-break switch has no arc quencher, such as arc chambers or arc chutes to
extinguish the arc but works only by stretching and breaking the arc in the air, usi ng
the arc horn, as shown in Fig. 5.3-15. These switches will open a circuit when only
line charging current is flowing but should not be used when a circuit is under
overload or short circuit conditions. The air-break switch has both the SWITCH
BLADE and the stationary contact assembly equipped with ARCING HORNS. The
switch sets on insulator stacks, which set on a firm base, all of which are part of the
switch.
DISTRIBUTION CUTOUTS AND ISOLATORS

ISOLATOR FUNCTION
The isolators covered have dual purpose- the link holder can be fitted with either a
fuse link or a solid link assembly. Distribution cutouts and Isolators are used in MV
distribution systems to protect line equipment and facilitate maintenance work.
Isolators are used in sectionalizing points on overhead lines. A section of the line can
be isolated for maintenance by opening the isolators on either side of the section to be
isolated. Cutouts have fuse elements and mounted high above the ground. They
protect the distribution system or the equipment connected to it from overloads and
faults. Distribution cutouts are used with installation of transformers, capacitors, cable
cutouts and sectionalizing points on overhead circuits.
316

Fig. 5.3-16 shows open link

and fuse cutouts used in
different distribution circuit
applications. It is used to
isolate a fault or overload
from circuits by blowing the
fuse due to fault or overload
currents higher than the
normal load current of the
Fig. 5.3-16 McGraw-Edison Isolator
circuit.
PARTS OF GANG OPERATED ISOLATO R

Major components of a
gang operated isolator
are shown in the Fig.
5.3-17. These isolators
are operated manually or
by electric motor. In
substations, manual
mode is used to operate
the isolator locally, while
motor operation is used
to open from the control
room. Isolators can be Fig. 5.3-17 Parts of Gang operated Isolator
LOCKED in OPEN
position.
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318

REVIEW EXERCISE
Complete The Following :
1. The following indicate s hazard source that can be eliminated simply by adherence
to proper safety on the job.
Following correct procedure of receiving _______________ line.
2. A lineman before starting any work must check for presence of voltage on a
_______________ line (induction effect from nearby parallel lines ) and install
temporary ground before starting any work directly on _______________ line for
equipment
3. It is an important safety aspect to install temporary ground first to a buried

_______________, then to the line and when removing, a reversed sequence of
de-installation is followed .
319

320

LESSON 5.4
CABLE SPLICING ACTIVITIES
321

322

LESSON 5.4
CABLE SPLICING ACTIVITIES
LESSON OVERVIEW
DESCRIPTION
In this lesson, Cable Splicing Activities, mainly Cable Receiving, Safety Aspects,
Work Procedures, Work Site Preparation, Direct Burial of Cable in the Ground and
Trenches, Cable Preparation, Joint and Termination, Pre-Commissioning Tests,
Ground Testing by Megger, Continuity Tests and Phase Rotation Tests are discussed.
OBJECTIVES
Upon completion of this lesson, the participants will be familiarized with:

∑ Cable Splicing Activities
∑ Cable Receiving, Safety Aspects and Work Procedures Work Site Preparation
∑ Direct Burial of Cable in the Ground and Trenches Cable Preparation
∑ Joint and Termination
∑ Pre-Commissioning Tests
∑ Ground Testing by Megger, Continuity Tests, Phase Rotation Tests
323

324

INTRODUCTION
A distribution cableman joints and terminates 15, 34.5, 69 kV cables to equipment.
Also, the cableman must be capable of performing pre-commissioning tests,
meggering, continuity and phase rotation tests. Official receiving of a dead and spiked
cable from the network operation crew is a safety aspect for the cableman crew, which
must be performed with the highest sense of responsibility. A responsible cableman
must be able to :
1. Follow safe procedures as per SECstandards in carrying out maintenance and
repair job duties.
2. Read joint material kit manufacturer 's instructions for installation.
3. Make precise measurements.
4. Clean joint and prop erly apply heat to shrinkable materials.
Cableman tools, materials, safety aspects and work procedures as well as the
importance of high quality workmanship are required in making MV U/G cable joints
and terminations.
1. LV & MV U/G CABLES

Power is generated and controlled by different equipment in the power network, but it
is transferred between 2 points of the netw ork via OH Lines or U/G Cables.
U/G Cables are constructed with insulated
conductors, depending upon the operating
Voltage. Extra factors are to be accounted for
when U/G cables are utilized in high Voltage
circuits to ensure safe and reliable service,
mechanically and electrically. These factors
are essentially grounding of the cable and
evenly distributing the electrical field inside
the cable. The following chart indicates U/G
Cables application in SEC Network at
different Voltage levels of the network. Fig. Fig. 5.4-1 Types of Cables for
different Voltage Levels
5.4-1 shows Types of Cables for different
Voltage Levels of Network.
325

Each Voltage level of the network is supplied by a particular type of U/G:

∑ Cable 230 kV Transmission Oil Filled
∑ Cable 69 kV Aluminum - XLPE insulated, sheathed, 1 * 400 mm2.
∑ 15 kV Al - XLPE insulated sheathed, armored, PVC jacket 3* 300 mm2.
∑ 600V, Al, XLPE 4 * 300 mm2 PVC jacket
2. LV. & MV U /G CABLE

LV U/G cables are designed for 600 V
Standard Cable consisting of:
a) Conductor - Aluminum to carry the
load current
b) Insulation - XLPE to insulate each
phase from the other and ground
c) Jacket - PVC to protect internal
components of the cable from the
soil and provide mechanical Fig. 5.4-2 LV U/G Cables
protection.
Note that the number of cores is 4 in Fig. 5.4-2.
3. MV U/G CABLES
The standard MV U/G Cables are 3*300 mm2 and 3*70 mm2 consisting of:
a) Conductor, Aluminum
b) Conductor S heath, semiconductor to control electric stresses on insulation and
to prevent insulation ionization.
c) Insulation
d) Insulation sheath, semiconductor to control and evenly distribute electric
potential stresses inside the cable.
e) Protection screen copper ground s the outer surface of insulation.
f) Bedding to keep circular shape of the cable.
g) Armour to provide mechanical protection of the cable.
h) Outer jacket, PVC, to protect the internal constituent of the cable from
humidity, dust and acids.
326

Fig. 5.4-3 shows

single and three cores
MV 15 kV U/G
Polymeric (XLPE -
Plastic) cables.
Fig. 5.4-3 Single and Three Cores MV Cables
4. PILC (PAPER INSULATED) MV U/G CABLES

Although it is non-standard, these cables still exist in service. It consists of the
following:
∑ Conductor, copper
∑ Insulation is oil impregnated paper
∑ Conductor and insulation semiconductor sheath
∑ Protection screen cotton tape with extruded wire
∑ Lead cover to protect internal parts of the cable
∑ Armour, metallic tape for mechanical protection
∑ Outer jacket PVC to protect the cable from soil, humidity, etc.
The following Fig. 5.4-

4 shows parts of the
PILC Cable.
Fig. 5.4-4 Three-Core Paper Insulated Cable PILC
327

5. CABLE INSTALLATION
MV U/G cables are installed by direct burial in the ground and in trenches, the depth
of the cable trench depending on the operating voltage of the cable. The following
Fig. 5.4-5 shows an LV U/Gcable trench with the required backfill layers and warning
tape.
The dimensions of U/G MV cable trenches are different than LV U/G cable trench
(depth and width), as shown in Fig. 5.4-6. The places for making splices (Splice Pit)
should be made with larger dimensions to enable a cableman to perform the joint on
MV cables. It is installed in the trench by pulling it over rollers placed in the trenc h to
prevent the outer jacket from being torn off .
Fig. 5.4-5 LV U/GCable Trench
Fig. 5.4-6
LV U/GCable Trench
328

The following Fig. 5.4-7 shows the operation of pulling MV cable in the trench (left
side) and the pull eye that clamps the cable end for pulling with straight and corner
rollers.
Fig. 5.4-7 Pulling MV Cable in Trench
6. CABLEMAN TOOLS
The cableman tools can be classified into the following categories:
1) Common Hand Tools: Hammer, Screw Drivers, Saw, Scale
2) Specialized Hand Tools: Electrician's Knife, Scorning Knife, Semi -Con Removal
Tools, Compression Tool and Dies, Soldering Tools, Heat Shrinking Tools
Besides the hand tools, the cableman journey truck contains the tent, the first aid box
and a water cooler.
329

HEAT SHRINK MATERIALS KITS

MV Straight joints and terminations to be performed by the following methods:
1. Manually by tape and compound
A Joints
2. Heat shrinkable
B Terminations 1. Pot head, filled with compound
2. Heat shrinkable
In SEC, however, the standard cable joint and terminati on material kits are Raychem
heat shrinkable for performing MV cable joints and termination. These material kits
consist of electric stress control insulation and outer tubes that shrink with applying
moderate heat flames onto the tube. Beside these tubes, the material kit includes
copper braid to join the ground screen for the two cables to be jointed with
semiconductor paint and masking tape to cover the connector between the two cables '
conductors. These connectors are not supplied as a part of the material kit.
7. JOINT AND TERMINATION PERFORMANCE

Performance of joints and termination can be briefed as follows:
A. JOINTS
1.Cable Receiving 5.Inserting the joint tubes
2.Work Site Preparation 6.Connector Compression
3.Cable Preparation 7.Applying the Mastic Tape
4.Core Preparation
8. Heat Shrinking Stress Tube (Black), the Isolating Tube (Red)
9. Over Sheath Tube (Red / Black)
10. Soldering the Copper Braid Tape to the ground screens
11. Wrapping the copper braid over the sheath tube (after it is cooled)
12. Installing the Metallic Armour Tube and the outer Jacket
13. Jointing Ground Screens Tape (Wire)
14. Masking Tape Application
330

TERMINATION
1. Cable Receiving
2. Work Site Preparation
3. Cable Preparation
4. Core Preparation
5. Soldering Copper Wire to Ground Screen
6. Inserting Stress Control Tube
7. Heat Shrinking Stress Tube ( Black)
8. Inserting Oversheath tube
9. Heat Shrinking Oversheath Tube ( Red)
10. Inserting Outbreak Tube
11. Heat Shrinking Gut break Tube ( Red)
12. Connector Compression
13. Install Outskirt Bells to Outdoor Termination
8.1 CONTINUITY AND PHASE IDENTIFICATION TE ST

Standard tests must be carried out on the MV cable before plac ing in service. The
continuity of the MV lines/cable conductors must be verified and identified for
each of the phases at both ends.
Test method and procedure are as follow:

Considering the 3 phase MV cable Section "AB", as shown in Fig. 5.4-8.
Fig. 5.4-8 Three Phase MV Cable Section "AB"
331

1. At ‘A’, designate each phase conductor as Phase R, Phase Y and Phase B,

respectively (from left to right facing the cable terminals).
2. Remove all ground con nections at both ends of the line Section ‘AB’.
3. At point ‘A’ install ground at the designated 'Phase R' conductor.
4. Select the lowest test voltage setting of the Megger test unit.
5. At point ‘B’, Megger each phase with respect to ground in turn.
The phase ind icating a zero Megger reading is identified or tagged as Phase R.
6. Upon completion of the Megger or MV DC test on any phase of the
cable or equipment, the phase terminals must be discharged prior to
disconnecting the test leads and proceeding to test on the other
phases. Due to the absorption effect associated with MV testing
which can cause dangerous voltage to remain on the cable conductor
long after the test has been completed, it is necessary that the
conductor should be adequately grounded for a conside rable time for
at least 4 times as long as the duration of the test voltage application .
7. Repeat the procedure for the other two phases (Y and B) to establish
continuity and phase identification and then properly tag the cable cores with
the standard design ation as identified.
8. Restore grounds at cable Section ’A -B’.
8.2 INSULATION RESISTANCE TEST

Insulation resistance test is performed with the use of the Megger to determine the
quality and condition of the cable. It is the most common test method to ensure
that neither shorts nor serious insulation damages exist prior to energization.
The recommended test voltage applied for the distribution cables/equipment is as
follows:
∑ 1000V DC test voltage for cables/equipment rated up to 1000V.
∑ 2500V DC test voltage for cables/equipment rated above 1000V.
Test method and procedure is, as follow:

Refer to the three phase MV line/cable Section ‘AB’ in Fig. 5.4-8 above.
332

∑ Remove ground connections at both ends of the cable Section ‘AB’.

∑ Select the 2500 VDC test voltage setting required for the insulation resistance test.
At point ‘A’ or ‘B’

∑ Measure the insulation resistance between each pair of conductors in turn (phase
to phase, i.e. between phases R and Y; phase Y and B and phases B and R
successively). Record the readings in the report.
∑ Measure the insulation resistance between each phase to ground (i.e. between
phase R to G; phase Y to G; and phase B to G). Record the readings in the report
Test results are acceptable if the test readings conform to the following criteria .
∑ Approximately uniform test readings between phases and phase to ground
insulation resistance.
∑ The test values obtained on all readings are 100 Meg-Ohms or greater.
If satisfactory, the MV cable is ready for commissioning.
TEST PROCEDURE FOR MV CABLE/RMU COMBINATION

Refer to the typical construction project, as shown in Fig. 5.4-9, involving a loop -fed
S/S insert to the existing distribution section. A new RMU is to be connected between
the existing cable section “AE” through two new cables, as required, terminated at
points “B” and “D”.
8.3 PRECOMMISSIONING TEST PROCEDURE FOR NEW PLANT

Considering the time limitation for the scheduled shutdown of the distribution
network, Construction Work Unit should complete the preliminary cable preparations
and pre-commissioning tests required for the new cable sections, switchgear and
transformer prior to the shutdown and their connection to the existing network.
The following pre-commissioning test procedure is recommended for the New Plant:
a) Perform continuity, phase identification and insulation resistance test of cable
section ‘FB’ before terminating to the new RMU at ‘B’ as follows:
333

For Continuity and Phase Identification :

1- Ensure that both ends of cable section ’FB’ are properly secured having adequate
clearances and are isolated from ground.
2- At point ‘F’, designate each core as ‘Phase R’, ‘Phase Y’ and ‘Phase B’ (take
note of the color markings of the cores for 3-core cables), respectively.
3- At point ‘B’ install ground to conductor designated as ‘Phase R’.
4- Select the lowest test voltage setting of the Megger test unit.
5- At point ‘F’, megger each phase with respect to ground in turn. The phase
indicating a zero Megger reading is identified/confirmed and tagged as ‘Phase
R’. The installed ground must be removed af ter the test.
PRECAUTION FOR SHOCK HAZARD

Upon completion of the Megger test on any phase, it must be discharged
before disconnecting the test leads and proceeding to test on the other phases.
6. Repeat the same procedure for the other two phases ‘Phase Y’ and Phase ‘B’.
For Insulation Resistance Test:

1. Select the 2500V DC test voltage setting required for the installation
resistance test.
2. Verify that all grounds have been removed from cable section FB.
3. At point ‘F’, megger the cable section ‘FB’ between phases (R-Y, Y-B and
B-R) to ensure that the insulation resistance is above minimum acceptable
value of 100 Mega-Ohms.
4. At point ‘F’ megger the cable section ‘FB’ for each phase to ground (R -G, Y-
G and B-G) and ensure that the insulation resistance is above acceptable
minimum value of 100 Mega-Ohms.
5. If the insulation resistance is found below the acceptable minimum, suitable
test and repair methods should be applied for restoration.
6. The cable section ‘FB’ is ready for termination for the new RMU.
334

Fig. 5.4-9
b) Undertake continuity, phase identification and insulation resistance test of cable
section ’GD’ before terminating to the new RMU at ’D’. The procedure is
repeated as per 8-3 (a) above for the cable Section ‘GD’ .
c) Cable sections ‘FB’ and ‘GD’ are then terminated to the new RMU at points ‘B’
and ‘D’ with reference to the identified phase designation or markings of the cable
and matching terminals of the RMU, respectively. It is essential that a consistent
marking system is used.
d) Carry out pre-commissioning test for the ground mounted transformer .
335

e) Based on the scheduled shutdown program, Operation Unit should carry out the
necessary switching procedures to isolate the existing cable section ‘AE’ and
applied grounds at points ‘A’ and ’E’ as per SEC standard practice.
f) Cable identification and spiking of cable section ‘AE’ at site ‘F/G’ and splicing to
the new cable sections.
Connection points ‘F’ and ‘G’ are coincident, as referred to Fig. 5.4-9(a), the
procedure is as follows:
∑ The cable section ‘AE’ must be identified, tagged and spiked at the work location
‘F/G’ prior to cutting the cable and proceeding with the required work.
∑ Before cutting single core cables, both sides of each core of the cable from the
point to be cut must be designated and tagged for proper identification.
∑ After cutting the cable section ‘AE’ at site ‘F/G’, the new cables are spliced
maintaining the same known and identified phase connections for both the loop -
in and loop -out cables.
∑ Connection points ‘F’ a nd ‘G’ are non -coincident at two distinct locations along
the circuit cable.
The procedure is , as referred to Fig. 5.4-10, as follows:

ß The cable section ‘AE’ must be identified, tagged and spiked at both work
locations ‘F’ and ‘G’ prior to cutting and proc eeding with the required work.
ß Before cutting single core cables, both sides of each core from the point to be cut
must be designated and tagged for proper identification at locations ‘F’ and ‘G’.
Fig. 5.4-10 Cable Section ‘AE’ identified, tagged and spiked
336

∑ After cutting cable section ‘AE’ at site ‘F’ and ‘G’ must
be checked for
consistency of phase identities as outlined in section 8.1.
∑ The new loop -in and loop -out cable section of the new S/S are then spliced
maintaining the same known and identified phase designations at points ‘F’
and ‘G’.
8.4 PRE-COMMISSIONING TEST PROCEDURE FOR COMPLETED
PLANT (NETWORK)
It is necessary that proper phasing should be consistently maintained for all
connections on the completed installation. The following pre-commissioning phase
test methods are recommended. It can be used for identification of phases on a
completed installation.
A) METHOD OF COLD PHASING
Referring to Fig. 5.4-11, cold phasing is

carried out on the completed network ‘A -
E’ as follows:
Fig. 5.4-11 Cold Phasing carried out on

completed Network ‘AE’
TEST PROCEDURE
1. Insert the appropriate test probes for the RMU at point ‘A’ and E’.
2. Remove all grounds from the complete installation cable section ‘AB’ and cable
section ‘DE’, respectively. Close switches ‘B’ and ‘D’ and open the MV fuse
switch of the new RMU at ‘C’.
3. Select the lowest test voltage setting of the Megger test unit.
4. At ‘A’ ground Phase ‘R’ and at ‘E’, megger each phase in turn to check that only
‘Phase R’ reads zero. Similarly ‘Phase Y’ and ‘Phase B’ are confirmed. The
installed grounds must be removed after each test.
337

5. If the phasing test results obtained are consistent with the established phase
identification at point ‘A’ and ‘E’, then phase matching is correct and acceptable.
If not, Construction Work Unit should remake terminations at ‘B’ and/or ‘D’ as
dictated by the phasing results.
The above procedure is repeated to confirm the corrected phasing.
B) METHOD OF HOT PHASING

Hot phase confirmatory test should be performed on a properly terminated and
completed installation. However, in certain special cases and for practical reasons,
hot phasing test may be applied on a partially completed termination without
boots. Referring to Fig. 5.4-11, the hot phasing test is undertaken as follows :
TEST PROCEDURE
1. Open and ground switches ‘A’, ‘B’, ‘D’, ‘E’ and fused switch ‘C’.
2. Insert the appropriate test probes for the RMU at ‘B’ and ‘D’.
3. Remove grounds at switches ‘B’ and ‘D’; switching the RMU to ‘OFF’ position.
4. Remove all applied grounds (if any, except C) and close
switches ‘A’ and ‘E’.
5. Using a suitably rated phasing voltmeter, identify and confirm matching phases
across the RMU test probes at ‘B’ and ‘D’. Matched phases will indicate a zero
reading.
6. Open and ground switches ‘A’ and ‘E’ and also ground s witches ‘B’ and ‘D’.
7. Place tag to matching phases ‘R’, ‘Y’ and ‘B’ at points ‘B’ and ‘D’.
8. Remove the test probes at ‘B’ and ‘D’ and replace the relevant covers and
padlocks.
TEST RESULTS
∑ If the tagged phases R, Y and B at switch ‘B’ are electrically direct ly opposite the
phase R, Y and B at switch ‘D’, then phase matching is correct and acceptable.
The completed installation is ready for commissioning.
∑ If the tagged phases are found not correctly positioned, it is necessary that
Construction Work Unit should remake the terminations at ‘B’ and/or ‘D’ to
provide proper phase matching.
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340

REVIEW EXERCISE
1. Complete the following:
i) Upon completion of the Megger or MV DC test on any phase of the cable
or equipment, the phase terminals must be_________ prior to
disconnecting the test leads and proceeding to test on the other phases.
ii) Due to the absorption effect associated with MV testing, which can cause
dangerous voltage to remain on the cable conductor long after the test has
been completed, it is necessary that the conductor should be adequately
_________ for a considerable time for at l east 4 times as long as the
duration of the test voltage application .
2. Read the following statements and then choose TRUE or FALSE

The recommended test voltage applied for the distribution cables/equipment is as
follows:
1000V DC test voltage for cables/equipment rated up to 1000V
2500V DC test voltage for cables/equipment rated above 1000V
3. MV U/G cables are installed by direct burial in the ground and in trenches with the
depth of the cable trench depending on the operating voltage of the cable.
What are the dimensions of U/G MV LV U/Gcable trenches for one cable as per
SEC standard?
4. Considering the time limitation for the scheduled shutdown to the distribution
network, Construction Work Unit should complete the preliminary cable
preparations and pre-commissioning tests required for the new cable sections,
switchgear and transformer prior to the shutdown and their connection to the
existing network. List these pre-commissioning tests?
341

ENGINEERS' COURSE

ELECTRICAL
Book 1 of 2
Edition : 2008 Feb.

Division : Syllabus Planning and Curriculum Writing
Division (SPCWD)
Department : Training Services Department (TSD)
342

Electrical 1 of 2

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ELECTRICAL – BOOK 1 OF 2

CRAFT APPRECIATION FOR ENGINEERS (CAFE)

MODULE / UNIT / LESSON PAGE

CRAFT APPRECIATION FOR ENGINEERS (CAFE)

CRAFT APPRECIATION FOR ENGINEERS (CAFE)

Upon completion of this course, the participants should be able to:

SEC NETWORK, STANDARDS

Upon completion of this lesson, the participants should be able to i dentify:

Task 1.1.1 Power System Simulator–Generation, Transmission and Distribution

SEC NETWORK OVERVIEW

Fig. 1.1 -1 SEC Power Network

Substations in the network serve different purposes, mainly, voltage level

Fig. 1.1-2 Substation

Also one HP of mechanical energy equals 746 watts of electrical energy. So a

Fig. 1.1-3 Prime Mover and Generator

Electric power is generated for community use by

Fig. 1.1-4 Electrical Network

1. HYDRO GENERATION PLANTS

2. STEAM GENERATION PLANTS

Fig. 1.1-6 Essential Components of Steam Electric Power Generation Plants

Steam Turbine Rankin Cycle

Fig. 1.1-7 Rankin Cycle for Steam Turbine

3. GAS TURBINE GENERATING PLANTS

Fig. 1.1-8 Components of Gas Turbine Plant

Gas turbine Brayton Cycle

Fig. 1.1-9 Gas Turbine Brayton Cycle

Combined Cycle Power Plant

Fig. 1.1-10 Combined Cycle Power Plant

4. INTERNAL COMBUSTION ENGINE PLANTS / DIESEL ENGINE PLANTS

Fig . 1.1-12 Power System

Fig. 1.1-13 P o wer Fl o w in a th eo r et ical Net wo r k

Long distance transmission lines serve two purposes:

Fig. 1.1-14 shows the components and

Fig. 1.1-14 Components and Switches of

Fig. 1.1 -15 Interconnected Transmission Power System

Fig. 1.1-16 Power Network Stages and Voltage Level

When it is necessary to de-energize a circuit, however, it is desirable to keep in

Bulk Supply Point

Fig. 1.1-17 Distribution Substation in SEC Network

Fig. 1.1-18 Different Stages of Power System

DUTIES AND RESPONSIBILITIES OF ELECTRICAL

POWER PLANT ELECTRICIAN (Fig. 1.1-19)

Fig. 1.1-19 Power Plant Electrician

DISTRIBUTION ELECTRICIAN (Fig. 1.1-21)

Fig. 1.1-21 Distribution Electrician

RELAY TECHNICIAN (Fig. 1.1-22)

INSTRUMENT TECHNICIAN (Fig. 1.1-23)

SCADA TECHNICIAN (Fig. 1.1-24)

TELECOM TECHNICIAN (Fig. 1.1-25)

Fig. 1.1-26 Water Treatment Plant

POWER PLANT OPERATOR (Fig. 1.1-27)

MATERIALS, TOOLS AND EQUIPMENT

SEC STANDARDS AND MANUALS

This lesson demonstrates ho w the Standards/Manuals are accessed to keep up -to-date

1- Distribution Materials' Specifications (SDMS)

13.8 & 33 kV Overhead Line Conductors (ACSR /

32-SDMS-01 SF6 Ring Main Units, 15 kV 1 04/2004

2- CONSTRUCTION STANDARD FOR OVERHEAD LINES (SDCS-01)

3- CONSTRUCTION STANDARD FOR UNDERGROUND

PART 1 Cable Trenches And Concrete Foundations 0 05/2005

Installation Of KWH Meters Inside Meter Rooms And

The (SDCS-02 – PART-3) construction standard specifies the design of wooden

The (SDCS-02 – PART-4) construction standard specifies the minimum requirements