King Fahd University of Petroleum & Minerals

College of Applied Engineering

Electrical Engineering Department

EE351 – Cooperative Work

Term 212-213
COOP Final Report

Power Distribution System

in Saudi Electricity Company

Prepared by:

Ali Alshams
ID: 201768990
COOP Advisor: Dr. Maan Kousa

Submission Date: 30/09/2022

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Abstract

Cooperative training (CO-OP) is a formalized procedure to get familiar with the work

experience and apply what we studied practically to benefit society. The CO-OP is

required to complete a B.S. degree at KFUPM. My training opportunity is at the Saudi

Electricity Company. Dammam, Saudi Arabia, starting on January 16, 2022, and

ending on August 11, 2022, for 28 weeks. There are five periods in the training

program. The first period is in the Dammam electricity services office with a duration

of six weeks, the second period is in the network planning department, lasted for

two weeks, the third period is in the construction department for seven weeks, and

the fourth period is in the operations department for six weeks. The last period is in

the maintenance department for eight weeks. The report aims to outline the training

experience at Saudi Electricity Company and to demonstrate two case studies about

the ring main unit and step-down transformer.

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Acknowledgments

I want to thank Allah first for creating us and allowing us to pray and work in life to

benefit ourselves and our society. Praise Allah for joining KFUPM university, finishing

the coop opportunity, and reaching the level to become a graduate inshallah. Also, I

would like to thank my family and friends for their continuous support before and

during the coop. A special thanks and appreciation to all Saudi Electricity Company

employees who helped me to gain all this knowledge that allowed me to have work

experience and understand what will be going on after graduating from university.

Lastly, I would like to thank my coop advisor Dr. Maan Kousa for his continuous

support and the coop coordinator Dr. Mahmoud Kassas for allowing us to have work

experience before graduating.

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Table of Contents
Abstract ...................................................................................................................................... ii
Acknowledgments..................................................................................................................... iii
List of Figures ............................................................................................................................. v
List of Tables ............................................................................................................................viii
List of abbreviations .................................................................................................................viii
Chapter 1: Introduction ............................................................................................................. 9
Chapter 2: Training activities ................................................................................................... 11
2.1 Identifying the work environment ................................................................................. 11
2.1.1 Dammam Electricity Services Office: ...................................................................... 11
2.1.2 Details of distribution substations: ......................................................................... 12
2.1.3 RMU and cable sizes: .............................................................................................. 14
2.1.4 Exemption requests: ............................................................................................... 16
2.1.5 Enhancement of the network: ................................................................................ 19
2.2 Construction department .............................................................................................. 21
2.2.1 Overview: ................................................................................................................ 21
2.2.2 Extension projects: .................................................................................................. 21
2.2.3 Operating projects: ................................................................................................. 22
2.2.4 Connection of meters: ............................................................................................ 25
2.3 Operation department ................................................................................................... 27
2.3.1 Network faults: ....................................................................................................... 27
2.3.2 Control department: ............................................................................................... 29
2.4 Maintenance department .............................................................................................. 29
2.4.1 Overview: ................................................................................................................ 29
2.4.2 Maintenance of substations ................................................................................... 30
2.4.3 Maintenance of meters: ......................................................................................... 32
2.4.4 Medium voltage machines:..................................................................................... 34
Chapter 3: First case study: Ring Main Unit (RMU) ................................................................. 36
3.1 Introduction: .................................................................................................................. 36
3.2 Analysis: ......................................................................................................................... 37
3.3 Components: .................................................................................................................. 42
3.4 Features and limitations: ............................................................................................... 44
3.5 Conclusion: ..................................................................................................................... 44
3.6 Recommendations: ........................................................................................................ 45
Chapter 4: Second case study: Step-down transformer .......................................................... 46
4.1 Introduction: .................................................................................................................. 46
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4.2 Analysis: ......................................................................................................................... 48

4.3 Components: .................................................................................................................. 51
4.4 Features and limitations: ............................................................................................... 52
4.5 Conclusion: ..................................................................................................................... 53
4.6 Recommendations: ........................................................................................................ 53
Conclusion & Recommendations ............................................................................................. 54
References ............................................................................................................................... 55

List of Figures
Fig.1 Mini pillar …………………………………………………………………………………………….………..12

Fig.2 Coincident factor ……………………………………………………….………………..……..…………13

Fig.3 Sizes of cables.……………………………………………………..……….…………………………….…14

Fig.4 Unit substation ………………………….….………………………….……..……….……………….….15

Fig.5 LV panel ……………………………………………………………………………………………….….……16

Fig.6 LV panel ……………………………………………………………………..…………...……………..……16

Fig.7 LV panel with 10 circuit breakers…………………………………………………………..………17

Fig.8 RMU next to LV panel …………………………………………………………………………………..17

Fig.9 Transformer behind LV panel ………………………………………………………...………….…17

Fig.10 RMU from inside …………………………………………………………………………………………18

Fig.11 Smart meters ………………………………………………………….………………………….………18

Fig.12 Mini pillar with fuses………………………………………………………………………..…………18

Fig.13 Oil switch ……………………………………………………………………………………………….…..19

Fig.14 Single line diagram of G/S ……………………………………………………………………….…20

Fig.15 Single line diagram of G/S transformers ……………………………………………….……20

Fig.16 Cables of LV panel …………………………………………………………..………..…….…………21

Fig.17 Black cable ……………………………………………………….…………………………...…..………22

Fig.18 Measuring wheel .…………………………………………………………………….………..………22

Fig.19 RMU shut down ………………………….….……………………………………………….…………22

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Fig.20 Placing cable lug ……………………………………………………………………………..……….…22

Fig.21 Hydraulic machine …………………………………………………………………………...….……23

Fig.22 Tightening cable lug ……………………………………………………………………….….………23

Fig.23 New LV panel …………………………………………………………………………………….….…..23

Fig.24 Old LV panel ………………………………………………………..………………………………….…23

Fig.25 Cable of size 630 𝑚𝑚2 ……………………………………………………………………..……..…24

Fig.26 Bus bars of transformer ………………………………………………………….……….……..…24

Fig.27 Phase indicator ……………………………………………………………………….…....……….…24

Fig.28 Single meter ………………………………………………………………………………..……….…..25

Fig.29 Meter boxes …………………………………………………………………………………………..…25

Fig.30 Meter box from inside …………………………………………………………………........……25

Fig.31 C.T meter ………………………………………………………..……………………………..…..….…26

Fig.32 C.T meter from inside ………………………………………………………………..…….….……26

Fig.33 Burned fuse ………………………………………………………….………………………….…….…27

Fig.34 New fuse ………………………………………………………………………..……….……………..…27

Fig.35 Megger device ………………………………………………………………………….………….…..28

Fig.36 Megger device testing ………………………………………………………………..…..……...…28

Fig.37 Generation trailer ………………………………………………………………….…………….……28

Fig.38 Controlling station ………………………………………………………………………….…….……29

Fig.39 Cables in the mini pillar ………………………..………….…………………….....…...……..…30

Fig.40 Digging process .…………………………………………………………………….………….…….…30

Fig.41 Ipec testing device ………………………….….…………………………………………..….………31

Fig.42 RMU from Lucy Electric …………………………………………………………………..…….……31

Fig.43 RMU from Schneider Electric …………………………………………………………...…..……31

Fig.44 Oil level and temperature ………………………………..…………………………….….………32

Fig.45 Oil level and temperature ……………………………………………………………….…….…..32

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Fig.46 Connection diagram of a meter ………………………………………………..……….…...…32

Fig.47 Components of meter box …………………………………………………………………………32

Fig.48 Quadratic meter before fixing ………………………………………………………….…..……33

Fig.49 Quadratic meter after fixing …………………………………………………………....…..……33

Fig.50 Burned meters and circuit breakers ……………………………………………………..…..34

Fig.51 Metered RMU ………………………………………………………………………….…………....…34

Fig.52 Specification of metered RMU ………………………....…………………….…..……..……34

Fig.53 Windings of metered RMU ………………………..……..………………..………..……….…35

Fig.54 Testing the windings of metered RMU ………………………..…………………..………35

Fig.55 Single line diagram of RMU ………………………………………………….……………….…37

Fig.56 RMU from outside ………………………………………………………..……..……...……….…38

Fig.57 RMU from inside …………………………………………………………………..….………..……38

Fig.58 Turning off the RMU ………………………………………………………..………….…..………38

Fig.59 Specification of RMU ………………………………………………………..……………..…...…38

Fig.60 Cables going to another RMU ………………………………………..….…….……..…..…..39

Fig.61 Cables coming to RMU ……………………………………………………………...….…………39

Fig.62 Cables going to transformer ……………………………………………………………….……39

Fig.63 Connection of RMUs…………………………………………………………….…..……….….…40

Fig.64 Single line diagram of G/S ………………………………………………………..…….…..…..41

Fig.65 Main components of RMU ……………………………………………………………..…….…42

Fig.66 Main components of RMU …………………………………………….…….………….………42

Fig.67 Earth fault indicator device ……………………………………………….…….……..….……43

Fig.68 Construction of the transformer ……………….…………………….………..….…...……46

Fig.69 Diagram of ideal transformer ………………………………………………..………….….…47

Fig.70 Transformer from outside ………………………………………..…..…………….…..………48

Fig.71 LV bushings of the transformer ……………………………………………..……….….……48

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Fig.72 Specification of the transformer ……………………………………..………….…..………48

Fig.73 Power transformer ………………………………………….…………………………...…….…..49

Fig.74 Three power transformers in the grid station …………………………….….…….….49

Fig.75 Distribution transformer …………………………………………….………………..….…….50

Fig.76 Auxiliary transformer ……………………………………………………………..…….…….….50

Fig.77 Components of the transformer …………………………………………….………..…….51

List of Tables

Table.1 Number of circuit breakers ……………………………………………..………..………15

List of abbreviations
SEC – Saudi Electricity Company
STC – Saudi Transformers Company
LV – Low voltage
RMU – Ring main unit
MRMU – Metered ring main unit
UDS – Uniform data system
U-S/S – Unit substation
G/S – Grid station
DL – Demand load
CBR – Circuit breaker rating
CF – Coincident factor
DF – Demand factor
ONAN – Oil natural air natural
OFAF – Oil forced air forced
N.O – Normal open
C.T – Current transformer
SF6 – Sulfur hexafluoride
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Chapter 1: Introduction

Saudi Electricity Company is one of the largest companies in Saudi Arabia. It supplies

electricity to every place in the country. The company delivers the power from the

generation plant to the transmission lines, then to the distribution stations, and

finally to the customer. SEC aims to deliver the electricity efficiently (power factor

greater or equal to 0.9) with maximum reliability (minimum shortage time) and using

technology (100% of smart meters by 2025 [1]) and most important is safety

(including using fuses, relays, switch gears, etc.). And for sure the safety of

employees (including wearing a helmet, rigid uniform of type cat 2 that resists the

fire).

SEC was founded in 2000 and now operates 45 power production facilities. The

company intends to grow its power generation capacity in the long run to satisfy

demand. [2]

The power is delivered to the customers from a distribution station, which steps

down the voltage from 115 kV to 13.8 kV and then to 230/400 V for the customer

through a way that will be discussed in this report. The distribution plant contains a

low voltage (LV) panel, ring main unit (RMU), underground cables, mini pillars, and

electricity meters. The distribution department has five periods in the training

program. The first is in the Dammam electricity services office, which prepares the

order of customers, spots the locations, studies the order by calculating the demand

load and voltage drop, and studies how to deliver the power by selecting the suitable

cable size. The second period with the network planning department dealt with
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higher voltage ratings, also discussing how to plan and improve the operation of the

distribution network. The third period in the construction department studies how

to supply electricity to big projects, connect the meters and provide technical

support. The fourth period in the operations department discusses network faults,

operation, checking, and controlling the network. The last period in the maintenance

department discusses the maintenance of the network, distribution stations, meters,

and medium voltage stations. This report will discuss a technical overview of all the

activities encountered in the five periods.

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Chapter 2: Training activities

2.1 Identifying the work environment

2.1.1 Dammam Electricity Services Office:

The department deals with the customers, inserting and analyzing the data in the

uniform data system (UDS), and provides the customers with the requirements

needed to supply electricity to their homes. For example, the customer must first fill

up the service request, provide the building’s construction license and engineering

diagram and make thermal insulation of the walls and roof to get the best efficiency,

especially in the summer. The invoices department deals with the monthly bills that

reach the customer; they calculate the price based on the number of units in the

building, kWh meter reading, and other factors.

The network planning department studies the best way to transfer the electricity

from the distribution station to the customer with less cost, maximum efficiency,

minimum losses, and maximum reliability. There are five types of order for the

electric meter: new meter, strength existing meter (increasing the ampere rating

because of the increase of customer loads), retail existing meter (dividing the meter

into several units based on the area), add meter (providing electrical service as

independent units on the existing building), temporary meter (for under-

construction building).

Saudi electricity company installed the meters in three cases; the first one is if the

number of meters is eight or less, then they will be installed in the front of the

building. The second case is that if 9-28 meters are needed: they will be installed in a
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suitable place that the company decides, for example, on the side of the building or

in a specific room inside the building. The last case is that if more than 28 meters are

needed, they will be installed in a specific room inside the building. For example,

malls and hospitals have a specific room for electricity meters.

Saudi electricity company measures the power at their station as apparent power (S)

and not real (P) in order to include the reactive power (Q) and hence minimize the

losses and improve the power factor as much as they can. The company uses two

voltage ratings; the old rating of 127/220 volt and the new rating of 230/400 volt.

2.1.2 Details of distribution substations:

There are two types of distribution substations; the first is the primary distribution

substation (grid station) which steps down the voltage from 69 kV or 115 kV to 13.8

kV. The second one is the secondary distribution substation (unit substation), which

steps down the voltage from 13.8 kV to 230/400 V, and it contains a Low voltage (LV)

panel, step-down transformer, RMU, then each unit substation (U-S/S) feeds many

mini pillars which are small boxes that feed 5-6 houses as shown in Figure 1.

Figure 1: Mini pillar

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The formula to calculate the demand load (DL) for a specific building is

𝐷𝐿 = 𝑁 ∗ 𝐶𝐵𝑅 ∗ 𝐷𝐹 ∗ 𝐶𝐹(𝑁) (2.1.2 − 1)

Where N is the number of meters and CBR is the circuit breaker rating in KVA given

in the formula below.

𝑐𝑢𝑟𝑟𝑒𝑛𝑡 𝑖𝑛 𝐴 ∗ 𝑠𝑒𝑐𝑜𝑛𝑑𝑎𝑟𝑦 𝑣𝑜𝑙𝑡𝑎𝑔𝑒 ∗ √3

𝐶𝐵𝑅 = (2.1.2 − 2)
1000

DF is the demand factor, and it is = 0.5 for residential buildings and 0.6 for

commercial ones. The secondary voltage is 220 V for the old rating (127/220 V) and

400 V for the new rating (230/400 V). CF(N) is the coincident factor, and it is = 1 for

the number of meters (N=1), as shown in Figure 2.

Figure 2: Coincident factor table

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The formula of voltage drop is

𝐷𝐿 ∗ 𝐿
𝑉𝐷% = (2.1.2 − 3)
𝐾

Where DL is the demand load, L is the cable's length in meters, and K is a constant

depending on voltage rating and the size of the cable.

2.1.3 RMU and cable sizes:

There are different sizes of cable that SEC uses, and the most famous ones are

4 X 500 𝑚𝑚2 , 4 X 300 𝑚𝑚2 , 4 X 185 𝑚𝑚2 , 4 X 70 𝑚𝑚2. where 4 is the number of

cores inside the cable (L1, L2, L3, N), with each core having a cross-section area of

500, 300, 185, 70 𝑚𝑚2 , respectively.

The 500 𝑚𝑚2 cable is used to link from the grid station to the unit substation, 300

𝑚𝑚2 cable is used to link from the LV panel in U-S/S to the mini pillar, 185 and 70

𝑚𝑚2 cables are used to connect from the mini pillar to the customer meter.

Figure 3: Different sizes of cables. From left to right: 4x185 with

aluminum protection around the circumference, 1x630, 4x70, 4x25
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The primary distribution plant consists of many unit substations, as shown in Figure

4. On the right is the RMU, which links the voltage (13.8 kV) from another RMU or

the grid station using underground cables. On the left is the LV panel with the step-

down transformer behind it (13.8 kV to 230/400 V). The transformer will step down

the voltage of RMU and pass it to the LV panel. The LV panel contains many circuit

breakers, each connected to the mini pillar or directly to the customer if his loads are

high.

Figure 4: Unit substation (U-S/S)

Table 1: Number of circuit breakers used in LV panels according to the voltage rating
and KVA rating of the transformer

127/220 V 230/400 V
500 kVA 8 4
1000 kVA 12 or 16 8
1500 kVA 14 or 24 10 or 12 or 14

Figure 5 shows the LV panel of the unit substation (U-S/S) from the inside, each iron

rod is called a bus bar, and the bus bar of the neutral line is half the width of the L1,

L2, and L3. In the blue is the current transformer (clamp meter) that measures the

current flowing to measure the load of each bus bar and hence helps the company

balance the loads.

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Figure 5: LV panel in the unit substation

Figure 6: Another shape of LV panel

Figure 6 shows another shape of the LV panel from inside that has 8 circuit breakers,

and according to Table 1, it could be either 500 KVA on the old voltage rating

(127/220 V) or 1000 KVA on the new voltage rating (230/400 V).

2.1.4 Exemption requests:

An exemption request is required when the overall load of the customer is greater

than 166 KVA (240 A). In order to supply enough power to the customer, the
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company will supply him from a nearby mini pillar, or the customer is forced to

prepare a space in his area for a new mini pillar to be installed.

Figure 7: LV panel with 10 circuit breakers Figure 8: RMU next to the LV panel

Figure 9: Transformer behind the LV panel that is used to step down

the 13.8 kV that comes from the RMU to 230/400 V in the LV panel
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Figure 10: RMU from inside Figure 11: Cables that come from mini pillar to 4
units or smart meters in the house

Figure 10 shows the RMU from the inside. It contains a circuit breaker and a

protection relay that protects it from overcurrent and predicts the type of fault. Also,

there is a gas gauge that indicates whether it is safe to turn on the RMU or not.

While Figure 11 shows the meter box that comes from the mini pillar and distributes

it to four smart meters, each one is serving a unit in the house. Also, SEC uses a small

current transformer inside the meter to measure the current and display it as a kWh

reading that will help in the pricing purposes.

Figure 12: Mini pillar from inside with fuses for safety. It
can feed five houses and has two spare capacities
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When the cable that links between RMUs fails, the oil switch shown in Figure 13 will

be used to feed the RMU from the other side. The oil switch is old, and now it is

aimed to be replaced by a 4-way RMU.

Figure 13: Oil switch

2.1.5 Enhancement of the network:

The network planning department cares about designing and planning from the

primary distribution substation or grid station (G/S) to the secondary distribution

substation or unit substations (U-S/S). The department cares about delivering the

power without shortage by supplying it from at least two grid stations. One is

primary, and the second is for backup. Each grid station supplies several U-S/S.

Figure 14 shows the single line diagram of the stations. There are three grid stations

at the top, and each rectangle represents a U-S/S. N.O is the normal open of the

RMU that will be closed in case the main G/S is down.

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Figure 15: Single line diagram of G/S

Figure 14: Single line diagram of G/S transformers and their feeders
and the U-S/S

Figure 15 shows the G/S with three step-down transformers (115/13.8 kV), each with

several feeders. A single U-S/S can be fed from two buses, one is primary, and the

other is backup, and it would be better if a single U-S/S is fed from two different grid

stations.

Two common types of transformer cooling are used in grid stations. First is oil

natural air natural cooling (ONAN), in which the air and oil are cooled by the ambient

temperature (it gives 50 MVA). The second one is oil forced air forced cooling

(OFAF), which has two oil tanks and cooling fans to cool the air (it gives 67 MVA for

the same transformer).

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2.2 Construction department

2.2.1 Overview:

The department deals with creating a new substation or shifting an existing one if it

covers the customer area. The department includes extension and operating

projects. The extension project studies the best cable size and location to extend the

cables from the low voltage panel to the mini pillar or directly to the customer if his

loads are high. The operating project operates the new substations after the

extension has been done. Also, they operated the old station after fixing or moving it

to another location.

2.2.2 Extension projects:

Figure 16 shows the cables that come from and to the low voltage (LV) panel. The

pink cable with a size of 4 X 500 𝑚𝑚2 comes from the grid station to the ring main

unit (RMU), then to the transformer to step down to voltage from 13.8 kV to

230/400 V, and finally to the LV panel. On the other hand, the black cable, which size

is 4 X 300 𝑚𝑚2 will be used to feed the mini pillar from the LV panel.

Figure 16: Cables that come from and to the LV panel

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Figure 17: Black cable with four cores Figure 18: Measuring wheel that is used
and each one with a cross-section area to measure the distances needed to
of 300 𝑚𝑚2 extend the cable

2.2.3 Operating projects:

The following figures below show a project where a new customer's cables will be

installed in the LV panel. Before doing that, the RMU should be turned off according

to the safety rules in SEC.

Figure 20: Process of placing the cable

lugs that connects the cable with the
Figure 19: An employee wearing safety
LV panel
clothes to shut down the RMU
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Figure 21: Hydraulic machine used to Figure 22: Cable lug after it has been
tight the cable lugs tightened and installed in the LV panel

Another project that belongs to the operation department is placing a new LV panel

near the old one since it is fully loaded. To do that, the RMU should be shut down

first, then placing the cables in the bus bars that come out of the transformer, as

shown in Figure 26. Each bus bar represents one phase, and for each phase, two

cables of size 1x630 𝑚𝑚2 will be used from the transformer to the LV panel.

Figure 23: New LV panel to be installed Figure 24: Old LV panel that is fully
loaded
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Figure 25: 1x630 𝑚𝑚2 cable

Figure 26: Installation of cable lugs in the
bus bars of the transformer

It is essential to check the sequence of the three phases (L1, L2, L3) before extending

the cables to the customer. To do that, a phase indicator device, as shown in Figure

27, is used to test the sequence of the phases. Three-phase machines need to be

connected in the correct sequence. For example, a three-phase motor that is used in

elevators should be connected in the proper sequence. Otherwise, it will rotate

oppositely.

Figure 27: Phase indicator device

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2.2.4 Connection of meters:

Figure 28: A single meter that has three-

phase cables coming from the mini pillar to
the circuit breaker and then to the smart
meter, and finally to the customer

Figure 29: Meter boxes

Figure 30: Meter box from inside

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Figure 29 shows the quadratic meter (60 A) and the service meter (30 A), and Figure

30 shows the quadratic meter from the inside. The electricity comes from the mini

pillar to the connection point, then to the circuit breakers, then to the smart meters,

and finally to the customer. Each meter is supposed to supply the power for one

floor in the house.

Figure 31: C.T meter Figure 32: C.T meter from inside

A current transformer (C.T) is used to step down the current (with a ratio of 200/5 A)

for the smart meter to read. Figures 31 and 32 show the C.T meter (200 A) to supply

power to a mosque. In the black is the new circuit breaker that can be turned on or

off by pressing a button, and in the future, it can be controlled remotely.

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2.3 Operation department

2.3.1 Network faults:

The network faults lie under the operation department, which operates, disconnects,

and fixes the network. There are many types of faults in the network. For example,

the fault could be in a cable that links between the mini pillar and the customer

meter or from the LV panel to the mini pillar. Also, it can be in any device in the

distribution network, like the fuse in the LV panel, as shown in Figure 33.

Figure 33: Burned fuse in the LV panel

Figure 34: New fuse after it has
been replaced

Another fault could be in the cables between the customer and the mini pillar or

between the mini pillar and LV panel. To identify that, a Megger device, as shown in

Figure 35, is used to test the insulation between phases of the cable, and therefore

we will know if they are good or need to be replaced. Figure 36 shows the testing of

two phases at a time. If the device shows a resistance greater than 1 GΩ, the

insulation between the two phases is good. If it is less than 1 GΩ, there might be a
 28

failure in the insulator, or the cables are touching (short-circuit), so they need to be

replaced. This test is done when the electricity is gone from the customer, and we do

not know where the problem is located.

Figure 35: Megger device Figure 36: Megger device that reads 90 GΩ,
which indicates good insulation between cables

Sometimes, replacing the cables needs hours because they will be extended

underground, leaving the customer with no electricity. To solve this problem, a

generation trailer, shown in Figure 37, will be used to supply the power temporarily

to the mini pillar or customer meter.

Figure 37: Trailer that generates electricity

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2.3.2 Control department:

The department is responsible for monitoring load conditions around the city,

maintaining the stability of the network, diagnosing and fixing the faults to ensure

that the network is restored quickly, and all of this while considering lower operating

costs.

Figure 38: Devices used for monitoring and operating the low voltage stations [3]

The system of controlling the electrical stations uses protection devices like

switchgears and numerical relays that have many benefits, including accurate load

measurement, monitoring the direction of power flow in the network, and accurate

decision-making to disconnect and locate the fault area.

2.4 Maintenance department

2.4.1 Overview:

This department has three types of maintenance: emergency or fault maintenance,

which includes fixing the machines and cables in low and medium voltages. For

example, fixing the cables between the mini pillar and customer meter, fixing the
 30

transformer if it fails, etc. The second type is periodic maintenance, which has a

schedule for regularly maintaining the machines. For example, the mini pillar, low

voltage panel, and transformer must be checked every 3-4 years. And the RMU must

be checked every six years. The last type is corrective maintenance, which fixes the

problems before they occur based on periodic inspection results.

Figure 39: Cables in the mini pillar that Figure 40: Digging process to fix the
is disconnected for maintenance underground cables

There was a fault in the cables between the mini pillar and the customer meter. The

cables in Figure 39 are insulated from the area where it has a fault. The cables on the

right side of the mini pillar are still connected and serve other customers. Figure 40

shows the tractor used for digging to extract the cables and fix them.

2.4.2 Maintenance of substations

The Ipec device in Figure 41 is used to spot the discharge in the cable by giving

signals that measure the discharging, then convert it to sound. The reading in Figure

41 shows a zero decibel, indicating there is no leaking in the cable and it has good

insulation.
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Figure 41: Ipec PD-SGS testing device

Figure 43: RMU from Schneider Electric

Figure 42: RMU from Lucy Electric

The RMUs in Figures 42,43 are opened to check their general operation and ensure

that the gas level is in the safe region. The RMU in Figure 42 is from Lucy Electric and

was manufactured in 2008. It uses fuses rather than relays or circuit breakers that

are found in the new RMUs. The problem with fuses is that they need to be replaced

each time after they burn.

 32

Figure 45: Maximum oil level and around

Figure 44: Oil level and temperature of the 25°C of temperature, which is good
transformer located inside the LV panel

2.4.3 Maintenance of meters:

Figure 46: Connection diagram of a meter. The

electricity goes from SEC to a circuit breaker, Figure 47: Components of the meter box
then to a meter, and finally to the customer
 33

The fault in the meter can be a meter that could not read and record the load’s kWh

although there is a current passing. Alternatively, it can be the opposite; the meter is

recording, but there is no current passing through, or the glass of the meter box is

broken, or the meter itself is burned. Several types of maintenance are required to

avoid these issues, including cleaning the meter and making sure the connection of

cables is safe and correct, as well as performing several tests using test devices to

measure the percentage error of the meter’s reading and to test the insulation and

the proper sequence of the cables.

Figure 48: Two quadratic meter boxes that have unclear

visuals from the glass and the arms of the cover are broken

Figure 49: New quadratic meter boxes after they have

been replaced
 34

Figure 50: Burned meters and circuit breakers that

required the whole box to be replaced

2.4.4 Medium voltage machines:

The medium voltage machines usually have a voltage rating of 1 kV-36 kV. The ring

main unit (RMU) is one of these machines and has a voltage rating of 13.8 kV as a

standard of SEC. Another type of RMU is the metered ring main unit (MRMU), as

shown in Figure 51, which is used to send the power directly to the customer

without using a transformer to step down the voltage. Instead, the customer

receives 13.8 kV, and he has his machines and transformers for his loads, this type of

RMU is used to supply the electricity to factories, hospitals, malls, or any building

with a high load.

Figure 52: Specification of the metered RMU

Figure 51: Metered RMU
 35

The RMU and metered RMU need to have some tests before operating it on the

customer to ensure it is safe. The windings of metered RMU should be tested to

make sure that they can handle specific amounts of voltage and to ensure that they

trip (disconnect) when giving them overcurrent from the Megger device, as shown in

figure 54. There are other tests for the metered RMU like insulation, meter, and

current transformer tests.

Figure 53: Windings of metered RMU

Figure 54: Testing the windings of metered RMU
 36

Chapter 3: First case study: Ring Main Unit (RMU)

3.1 Introduction:

The ring main unit (RMU) is a machine used in the secondary distribution substation

(unit substation), along with the transformer and low voltage panel. The RMU

contains three sides (3-way RMU) as shown in Figure 55; one is coming from the grid

station or another RMU, and the second is going to another RMU to feed it, the third

one is going to the transformer to step down the voltage and then send it to the low

voltage panel. Also, it can have four sides (4-way RMU); an extra one is standing by

to feed another transformer for backup. Another type is MRMU or metered ring

main unit. It is similar to RMU but feeds only one customer with high loads. The RMU

contains a circuit breaker and a protection relay (switchgear) that protects it from

overcurrent and detects the type of fault. Also, it has Sulfur hexafluoride (SF6) gas

used to insulate the circuit breaker, busbar, and electronics inside it. This case study

will analyze the RMU used in the distribution network of SEC, address its features

and limitations, and recommend some solutions.

 37

3.2 Analysis:

Figure 55: Single line diagram of a typical RMU [4]

The single line diagram of a typical RMU is shown in Figure 55, where the right side is

the local line that goes to the transformer to step down the medium voltage (13.8 kV

in SEC) and send it to the low voltage panel as a low voltage (230/400 V). where the

other two sides go from and to another RMU in different areas.

RMU is reliable, safe, easy to maintain and replace. The RMU is available in different

voltage ratings depending on requirements, and it is suitable for indoor and outdoor

installations. The RMU cabinet is connected by input and output cables, and one

cable goes to the transformer. Most of the elements in the RMU (including load

breaker, busbar, and terminals) are placed in an SF6 gas tank resistant to

environmental factors. The switchgear of RMU has circuit breakers that contain self-

powered relays, which are more reliable than fuses. The switchgear can control the

circuit and isolate it from the failed equipment. Also, it protects the equipment from

short-circuiting and overload [5].

 38

Figure 56: RMU from outside Figure 57: RMU from inside

Figure 58: An employee taking all kinds of Figure 59: Specification of the RMU
safety to turn off the RMU
 39

Figure 60: Cables that go out to another Figure 61: Cables that come from the grid
RMU station or another RMU

Figure 62: Cables that go to the

transformer
 40

Figure 63: An example of how RMUs are connected [6]

The RMUs in the top of Figure 63 are 4-way RMUs, which means that they take

power from one RMU, send it to another, and feed two locals, which are two RMUs.

In the middle, there are 3-way RMUs that feed a transformer to step down the

voltage and send it to a factory (ex: 13.8 kV/400 V). The RMUs in the bottom are also

3-way RMUs. One of them is feeding the grid, then the voltage will be stepped down

before reaching the house (ex: 13.8 kV/220 V), and the other receives power from

the wind turbine.

 41

Figure 64: Single line diagram of the grid

stations (G/S) in the Azizia neighborhood

Figure 64 illustrates how RMUs are linked together. The power comes from the

primary distribution substation (grid station). For example, RMUs from R-7 to 41520

on the left are fed from G/S #341. After that, a normal open (N.O) switch will be

closed if G/S #341 is failed, and its RMUs will be fed from the backup station, which

is G/S #351. That will feed, in this case, the RMUs from 41252 to 41543 going up to

R-7.
 42

3.3 Components:

Figure 65: Main components of the RMU [6]

Figure 66: Main components of the RMU

 43

Figure 66 shows the RMU that was seen with one of the employees. Where 1

represents the protecting relay that can be controlled manually and remotely in the

future. While 2 represents the SF6 gas pressure gauge, an employee must check it

before turning on or off the RMU. 3 represents the area where the rod in Figure 58

must be inserted to turn on or off the power that goes to the transformer. 4 and 5

represent the switches for the incoming and outcoming cables for the RMU,

respectively. Another component of the RMU is the earth fault indicator, as shown in

Figure 67, which detects the short-circuit fault and phase-to-earth fault with the help

of the current transformer.

Figure 67: Earth fault indicator

 44

3.4 Features and limitations:

The main features of the RMU can be summarized in five points:

• It is easy to install and maintain and can improve the network's reliability by

using protection circuits and having self-tested devices inside it.

• It is unaffected by the external environment with the use of SF6 gas that

insulates the circuit breaker, busbar, and terminals.

• The maintenance cost is low and has a life cycle of more than 30 years.

• It can feed to more than one transformer with easy switching.

• It can be connected remotely by the distribution center due to its smart

electronics and communication capabilities.

The main limitations of RMU can be summarized in two points:

• It cannot tolerate high voltage values like 300 kV used in transmission lines.

• It could fail if the SF6 gas leaked out from the tank since the moisture can

damage the busbars and terminals of RMU.

3.5 Conclusion:

This case study has discussed the ring main unit (RMU) used in the secondary

distribution substation by explaining its principle, showing its components, and

concluding with its features and limitations to the network.

 45

3.6 Recommendations:

• RMU should only be used in medium voltage ratings (less than 36 kV) to

avoid damaging it.

• Regular inspections are required, especially for the SF6 gas, to ensure that

the gas level is sufficient, and the gas tank is in good condition to avoid

leaking.
 46

Chapter 4: Second case study: Step-down transformer

4.1 Introduction:

The transformer is a device that transfers electricity between two sides with

different voltages and currents at the same frequency using electromagnetic

induction. A step-down transformer is used to step down the voltage of the

transmission lines (115 kV) and send it to the grid station (13.8 kV). Also, it is used in

the secondary distribution substation (unit substation), where the voltage of the ring

main unit (13.8 kV) is stepped down to around 220 V that goes to the LV panel, then

to the mini pillar or directly to the customer if his loads are high.

Figure 68: Basic construction of the transformer [7]

A step-down transformer contains primary and secondary windings wrapped around

a magnetic core, as shown in Figure 68. The magnetic core is a set of laminated

sheets of steel with tiny gaps between them to ensure that the magnetic field

remains in the core. The primary winding is connected to an AC source that

generates an alternating magnetic flux inside the magnetic core; this flux goes to the
 47

secondary winding and hence generates a current inside it; this current is greater

than one of primary winding since the voltage is stepped down, and this is because

the number of turns in the secondary winding is less than the one of primary winding

𝑉𝑝 𝑁𝑝 𝐼𝑠
according to the formula 𝑉𝑠 = = 𝐼𝑝, where Vp and Vs are the voltages in the
𝑁𝑠

primary and secondary winding, respectively. Np and Ns are the number of turns in

the primary and secondary winding, respectively. Ip and Is are the primary and

secondary winding currents, respectively. This case study will analyze the step-down

transformer used in the distribution network of Saudi Electricity Company, address

its components, features and limitations, and recommend some solutions.

Figure 69: Diagram of the ideal transformer [8]

 48

4.2 Analysis:

Figure 70: Transformer from outside Figure 71: Bus bars (LV bushings) inside the
transformer

Figure 72: Specification of the transformer

 49

The transformer in Figure 72 is made by the Saudi Transformers Company (STC). It

has a rating of 1000 KVA with 3 phase wires and 60 Hz frequency. It can receive a

voltage on the primary side from 13.11 kV to 14.49 kV, and the secondary side has a

voltage rating of 230/400 V (new voltage rating in SEC). The vector group of this

transformer is Dyn 11, where D stands for delta connection in the primary winding, y

stands for wye (star) connection in the secondary winding, n stands for a neutral line

connected in the secondary winding, and 11 stands for 11 o’clock (30 degrees) phase

leading, where LV winding leads HV winding by 30°. This transformer's cooling is

ONAN (natural oil air), which depends on the ambient temperature to cool the air

and oil.

In grid stations, power transformers are used to step down the voltage coming from

the transmission lines (115 kV) and step it down to 13.8 kV, and then it goes to many

circuits that each one of them goes to the RMU found in the unit substation (U-S/S).

The power rating of power transformers in SEC is from 50 to 67 MVA.

Figure 73: Power transformer Figure 74: A grid station that has three
(115 kV - 13.8 kV) power transformers
 50

After that comes the distribution transformers that step down the voltage from RMU

(13.8 kV) to 230/400 V and send it to the LV panel. The power rating of the

distribution transformer in SEC varies from 500 to 1500 KVA. Another type similar to

the distribution transformer is the auxiliary transformer, which is used to step down

the voltage that comes to the grid station and feed it back to its loads like air

conditioning, lights, etc.

Figure 75: Distribution transformer

(13.8 kV - 230/400 V)
Figure 76: Auxiliary transformer in the
Nakheel grid station
 51

4.3 Components:

Figure 77: Main components of the step-down

transformer [9]

1- HV Bushing: used to connect the primary winding with the cables that come from

RMU

2- LV Bushing: used to connect the secondary winding with the cables that go to the

LV panel

3- No Load Tap Changer: used to keep the secondary voltage stable by controlling

the turn ratio of the winding

4- Core Clamps

5- LV Coil
 52

6- Transformer Tank

7- Pressure Relief Valve: used to evacuate the pressure inside the transformer when

exceeding the nominal values (0.3/0.43 bar)

8- Top Oil Thermometer: used to measure the highest oil temperature during a

specific period

9- Oil Level Indicator

10- Corrugated Fins: used to improve cooling efficiency

11- Core

12- HV Coil

13- Roller: to move the transformer if needed

Also, it contains fuses or circuit breakers to protect it from short-circuit faults or high

transient voltage.

4.4 Features and limitations:

The features and limitations of the transformer can be summarized in the following
points [10]:

Features of the transformer:

• Easy control of the AC voltage and current over the same frequency.

• Cheap implementation and maintenance costs.

• It has no moving parts hence less faults.

 53

• Windings are electrically isolated by using electromagnetic induction to

transfer power between them.

Limitations of the transformer:

• Cannot work with DC voltage.

• Continuous need for cooling.

• Occupying large areas that cannot be fit in small places.

4.5 Conclusion:

This case study has discussed the step-down transformer used in the secondary

distribution substation by explaining its principle, showing its components, and

concluding with its features and limitations.

4.6 Recommendations:

• Accurate planning for the suitable size of the transformer is necessary, since

it occupies a large area, and the area is directly related to the amount of

power needed.

• A regular inspection is needed, especially for the oil level and cooling system,

to extend the life cycle of the transformer.

 54

Conclusion & Recommendations

Throughout the Coop training in Saudi Electricity Company, I had the opportunity to

engage in the work environment, and this helped me to improve my technical and

communicational skills. Furthermore, I have learned and observed how each

department in SEC is working and how they are connected and cooperated with each

other. I recommend everyone who is interested in the power systems and the

journey of delivering the electricity (from generation to transmission until

distribution) to apply for a COOP or summer training at SEC. Also, I recommend SEC

to investigate more in the training program and put a plan to cover all the sectors of

the company for the eastern branch since it only provides training in the distribution

department, unlike the central and western branches that cover all of them

(generation, transmission, and distribution).

 55

References

[1]: Overview. (n.d.). SEC. Retrieved from https://www.se.com.sa/ar-

sa/invshareholder/Pages/strategy.aspx

[2]: Saudi Electricity Company. (2022, March 18). Wikipedia. Retrieved from

https://en.wikipedia.org/wiki/Saudi_Electricity_Company

[3]: Electric voltage control room of a plant. (n.d.). Retrieved from

https://depositphotos.com/12672511/stock-photo-electric-voltage-control-room-

of.html

[4]: Edvard. (2015, February 11). Ring Main Unit as an important part of secondary

distribution substations. EEP. Retrieved from https://electrical-engineering-

portal.com/ring-main-unit-rmu-as-an-important-part-of-secondary-distribution-

substations

[5]: What is a Ring Main Unit (RMU)? (n.d.). Retrieved from

https://vietnamtransformer.com/our-news/what-is-a-ring-main-unit-rmu

[6]: Medium Voltage Ring Main Unit. Alfanar. (n.d.). Retrieved from

https://www.alfanar.com/catalogs/power_distribution_control/RMU.pdf

[7]: Transformers | Explaining The Basics of Transformers. (n.d.). Retrieved from

https://www.galco.com/comp/prod/trnsfmrs.htm
 56

[8]: Simulation of Single Phase Transformer with Different Supplies - Scientific

Figure on ResearchGate. Retrieved from https://www.researchgate.net/figure/Ideal-

transformer-circuit-diagram_fig1_224937629

[9]: Distribution transformers - Alfanar. (n.d.). Retrieved from

https://www.alfanar.com/catalogs/transformers/Distribution_oil_transformer.pdf

[10]: Advantages and disadvantages of transformers. (2021). Retrieved from

http://www.electricalterminology.com/advantages-and-disadvantages-of-transformers/