Ge00-00-910-ak-e-sp-5001-000.e02

Document No. Revision:

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Engineering Specification MEDIUM VOLTAGE SWITCHGEAR Document Number: GE00.00.910.AK.E.SP.5001.000

E02

ISSUED FOR ENQUIRY

PM

18.08.04

D01

DETAIL DESIGN APPROVAL

PM

23.04.04

Rev

Description

By

Date

Chk’d

Date

App’d

Date

Document No. Revision:

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Rev.

Para.

Revision Description

Hold No.

Para.

Description of Hold

Project Specification - High Voltage Metal Enclosed Switchgear and Motor Control Centres

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TABLE OF CONTENTS 1

INTRODUCTION

1.1

PURPOSE

1.2

DEFINITIONS

1.3

UNITS OF MEASUREMENT

2

CODES, STANDARDS, REGULATIONS AND REFERENCES

2.1

CODES, STANDARDS, REGULATIONS AND REFERENCES

2.2

ORDER OF PRECEDENCE

2.3

DEVIATIONS AND EXCLUSIONS

3

HEALTH, SAFETY AND ENVIRONMENTAL REQUIREMENTS

3.1

ENVIRONMENTAL CONDITIONS

3.2

AREA CLASSIFICATION

3.3

HEALTH, SAFETY AND ENVIRONMENTAL REGULATIONS

4

GENERAL DESIGN REQUIREMENTS

4.1

OPERATING REQUIREMENTS

4.2

DESIGN LIFE

4.3

NOISE LIMITS

4.4

UTILITIES

4.5

PROVEN EQUIPMENT CRITERIA

4.6

TOTAL COST OF OWNERSHIP

5

EQUIPMENT DESIGN AND MANUFACTURING

5.1

ELECTRICAL SYSTEM

5.2

STRUCTURAL AND MECHANICAL REQUIREMENTS

5.3

CIRCUIT BREAKERS

5.4

MOTOR STARTERS

5.5

BUSBARS

5.6

EARTHING

5.7

SECONDARY WIRING

5.8

CABLE TERMINATIONS

5.9

AUXILIARY SUPPLIES

5.10

INSTRUMENT TRANSFORMERS

5.11

METERING, PROTECTION, CONTROL AND INDICATION

5.12

ANTI-CONDENSATION HEATERS

5.13

ELECTROMAGNETIC COMPATIBILITY (EMC)

5.14

MATERIALS OF CONSTRUCTION

5.15

PAINTING AND COATING

5.16

NAMEPLATES, MARKING AND LABELLING

6

TESTING AND INSPECTION

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6.1

GENERAL

6.2

MATERIAL CERTIFICATION

7

PRESERVATION, STORAGE, HANDLING AND SHIPPING

8

WEIGHT

9

INSTALLATION, SITE TESTING AND COMMISSIONING

10

MAINTENANCE REQUIREMENTS

11

SPARE PARTS AND SPECIAL TOOLS

11.1

SPARE PARTS

11.2

SPECIAL TOOLS

12

DOCUMENTATION

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1

INTRODUCTION

1.1

PURPOSE

1.1.1

This specification defines the minimum technical requirements for High Voltage Metal Enclosed Switchgear and Motor Control Centres on onshore and offshore production facilities to be operated by Agip Kazakhstan North Caspian Operating Company (Agip KCO).

1.1.2

Particular requirements for the equipment are detailed in the requisition, on the one line diagram and on the data sheets.

1.2

DEFINITIONS

1.2.1

The COMPANY is the party that initiates the project and ultimately pays for its design and construction. The Company will generally specify the technical requirements. The Company may also include an agent or consultant authorised to act for, and on behalf of, the Company.

1.2.2

The CONTRACTOR is the party that carries out all or part of the design, engineering, procurement, construction, commissioning or management of a project, or operation or maintenance of a facility. The Company may undertake all of part of the duties of the Contractor.

1.2.3

The SUPPLIER (MANUFACTURER / VENDOR) is the party that manufactures or supplies equipment and services to perform the duties specified by the Company or Contractor.

1.2.4

The word shall indicates a requirement

1.2.5

The word should indicates a recommendation

1.2.6

Abbreviations

1.3

ac

-

Alternating Current

Agip KCO

-

Kazakhstan North Caspian Operating Company

dc

-

Direct Current

ESD

-

Emergency Shutdown

CT

-

Current Transformer

HV

-

High Voltage

IDS

-

Inspection Data Sheet

IEC

-

International Electrotechnical Commission

IP

-

Ingress Protection

ISO

-

International Organization for Standardization

MCB

-

Miniature Circuit Breaker

MCC

-

Motor Control Centre

PLC

-

Programmable Logic Controller

SDRS

-

Supplier Documentation Requirements Schedule

IPCD

-

Integrated Protection and Control Device

SI

-

Système International d' Unités

UNITS OF MEASUREMENT In general, the International System of units (SI) shall be used.

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2

CODES, STANDARDS, REGULATIONS AND REFERENCES

2.1

CODES, STANDARDS, REGULATIONS AND REFERENCES

2.1.1

In conjunction with this Specification, the Codes, Standards, Regulations and References listed below shall be applicable. Equivalent alternatives may be offered, however these shall be identified and based on mutual agreement.

2.1.2

Project Specifications Refer to list in the Requisition

2.1.3

Kazakh Regulations, Codes and Standards The following regulations, codes and standards shall be applied:

2.1.4

PUE

-

Rules for Electrical Installation

VSN 59-88

-

Electrical Equipment in Residential and Public Buildings

SN 174-75

-

Guidelines for Design of Power Supply for Industrial Plants

RD 34.20.185-94

-

Guidelines for Design of Urban Power Supply Networks

SNIP 3.05.06-85

-

Electrical Apparatus

18220f 07.12.2000g

-

Code of Electric Power Usage

GOST 28668.1-91

-

GOST 22789-94

-

Industry Codes and Standards The equipment and installations shall comply with the latest issues and most recent revisions or amendments of the Statutory Requirements and IEC Recommendations, current at the time of placing the purchase order including, but not limited to the following: IEC 60044

-

Instrument Transformers – Part 1: Current Transformers Part 2: Induction Voltage Transformers

IEC 60051

-

Direct acting indicating analogue electrical measuring instruments and their accessories

IEC 60073

-

Colours of indicator lights and push buttons

IEC 60186

-

Voltage Transformers

IEC 60255

-

Electrical Relays

IEC 60269

-

Low voltage fuses.

IEC 60282

-

High voltage fuses

IEC 60298

-

Alternating current metal enclosed switchgear and controlgear for rated voltages above 1 kV and up to and including 52 kV.

IEC 60417

-

Graphic symbols for use on equipment

IEC 60420

-

High-voltage alternating current switch-fuse combinations.

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IEC 60445

-

Identification of equipment terminals and of terminals or certain designated conductors. Including general rules for an alphanumeric system

IEC 60470

-

High-voltage alternating current contactors and contactor based motor starters.

IEC 60521

-

Alternating current watthour meters.

IEC 60529

-

Degrees of protection provided by enclosures (IP Code)

IEC 60617

-

Graphic symbols for diagrams

IEC 60644

-

Specification for high-voltage fuse links for motor control circuit applications.

IEC 60694

-

Common clauses for high-voltage switchgear and controlgear standards

IEC 60715

-

Dimensions of low-voltage switchgear and controlgear. Standardized mounting on rails for mechanical support of electrical devices in switchgear and controlgear installations.

IEC 60947

-

Low-voltage switchgear and controlgear. Part 5 SEC1 Circuit devices and switching elements- electro-mechanical control circuit devices.

IEC 61000

-

Electromagnetic compatibility (EMC)

IEC 62271

-

High-voltage switchgear and controlgear – Part 102 Alternating current disconnectors and earthing switches

For the purposes of this Specification, the word ‘should’ shall be replaced by the word ‘shall’ wherever it appears in the above referenced standards. Although not supplied for installation in a member country of the European Economic Area, the equipment shall be supplied in accordance with all applicable European Union Directives. Particular attention should be paid to: • • • •

Safety Electromagnetic Compatibility Machinery CE Marking

2.2

ORDER OF PRECEDENCE

2.2.1

The order of precedence shall be as follows: 1) 2) 3) 4) 5) 6)

Material Requisition Data Sheets and Drawings including One Line Diagrams, Schematics etc. This Specification Project Specifications International and National Regulations, Codes and Standards Industry codes and standards referenced herein.

2.2.2

Should there be conflict between the requisition, data sheets, specifications, codes and standards or lack of clear definition as to the applicability of any specification or standard, the SUPPLIER shall obtain a written clarification from the Purchaser before proceeding.

2.2.3

Should there be any conflict between English and Russian versions of the applicable documents, the English version shall take precedence on all documents except the Kazakh (National) Codes and Regulations, where the Russian version shall take precedence

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2.3

DEVIATIONS AND EXCLUSIONS

2.3.1

The SUPPLIER shall identify and list all deviations and exclusions to the documents and associated requirements listed in Section 2.1

2.3.2

Unless deviations / exclusions are specifically identified by the SUPPLIER in the bid proposal and agreed by the Purchaser, the SUPPLIER shall be deemed to have confirmed full compliance with all the documents listed.

3

HEALTH, SAFETY AND ENVIRONMENTAL REQUIREMENTS

3.1

ENVIRONMENTAL CONDITIONS

3.1.1

Equipment shall be suitable for long term, continuous operation at part or full load on the electrical system having the characteristics specified on the data sheet.

3.1.2

Equipment shall be suitable, in all respects, for operation in the site environmental and service conditions as listed in the project document Design Basis Onshore and Offshore Process Facilities plus Associated Pipelines, Document No. KE01.00.000.KD.R.YD.0001.000.

3.1.3

Equipment and materials conforming to this document shall be suitable for operation at their nameplate ratings in the conditions stated above and as follows: Units

Offshore

Onshore

Maximum external equipment design temperatures

°C

+42

+45

Minimum external equipment design temperatures

°C

-36

-36

Maximum internal equipment design temperatures

°C

+40

+40

Minimum internal equipment design temperatures

°C

+5

+5

3.1.4

The SUPPLIER shall state the maximum and minimum operating temperature of the equipment as well as details of any operational constraints that may be necessary in case of such events as the loss of HVAC for long periods. The SUPPLIER shall provide heat dissipation values in order for the design of the HVAC to be completed.

3.1.5

The atmosphere shall be regarded as saliferous and corrosive.

3.2

AREA CLASSIFICATION All equipment shall be suitable for installation & operation in a non-hazardous environment

3.3

HEALTH, SAFETY AND ENVIRONMENTAL REGULATIONS The SUPPLIER shall be responsible for ensuring that the goods and services supplied meet all applicable regulations on health, safety and environmental issues. The equipment shall be designed to operate safely and satisfactorily at all expected combinations of process, utilities, climates and environmental conditions including those at start-up, shutdown, part load operation, and emergency cases while retaining the overall system security, reliability and availability.

4

GENERAL DESIGN REQUIREMENTS

4.1

OPERATING REQUIREMENTS

4.1.1

Operation of a circuit breaker or contactor will normally be from a remote location.

4.1.2

The switchgear and controlgear shall be designed to minimise risk of an internal short circuit. It shall also provide for personnel and operating safety during all operating conditions, inspections, maintenance, the connection of main, control and auxiliary cables and the equipping and commissioning of skeleton panels whilst the switchgear is energised and in operation.

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4.1.3

It shall be possible to safely carry out work on an individual panel including power, control and auxiliary cables when isolated, with busbar shutters padlocked closed and with the remainder of the switchgear and controlgear live, without danger from contact with live parts.

4.1.4

Under extreme conditions of major short circuits or mal-operation there shall be no danger to persons in the vicinity of the switchgear and controlgear. Interlocks and covers shall be provided to prevent incorrect or unsafe operation and to prevent access to live parts.

4.1.5

Circuit breakers shall be designed to withstand a minimum of three complete operations an hour with no longer than fifteen minutes between operations.

4.1.6

The maximum difference in time between the circuit breaker phase contacts touching during closing shall not exceed one half cycle. The maximum difference between the instant of contacts separating during opening shall not exceed one half cycle.

4.1.7

Each cubicle containing withdrawable circuit breaker or contactor shall be fitted with shutters which automatically cover the busbar and circuit apertures when the circuit breaker or contactor is disengaged.

4.1.8

Provision shall be made to padlock the following: •

Earth switches in the closed position

•

Busbar and circuit aperture shutters in the closed position.

•

Circuit breakers and contactors in the test and isolated position.

•

Voltage transformers in the engaged and disengaged positions.

Labels shall be provided to clearly indicate the above positions. 4.2

DESIGN LIFE

4.2.1

The equipment shall have a minimum design life of 40 years, under the specified stated service conditions. The SUPPLIER shall state in the tender the anticipated service life of the equipment, assuming maintenance in accordance with the SUPPLIER’S recommendations.

4.2.2

All equipment shall be brand new and of recent manufacture. Used, re-conditioned or equipment that has been held on long-term storage will be rejected.

4.3

NOISE LIMITS Where applicable, equipment noise limits will be specified on the associated equipment data sheets.

4.4

UTILITIES SUPPLIER shall advise details of preferred power supply requirements for switchgear tripping, closing and charging supplies and the expected electrical load demand.

4.5

PROVEN EQUIPMENT CRITERIA

4.5.1

Only equipment of proven reliability in similar service conditions, shall be included in the SUPPLIER’S bid proposal (prototypes shall not be proposed). The SUPPLIER shall provide the related necessary evidence (reference lists with installation dates and run-hours accumulated by date etc.). The equipment shall have equivalent design features to the proposed equipment.

4.5.2

Where the requirements above prevent the application of the lastest technology, the SUPPLIER may submit a second alternative proposal incorporating the latest technology features for evaluation by the Purchaser. This alternative proposal shall specifically identify the un-proven features and state their advantages.

4.6

TOTAL COST OF OWNERSHIP

4.6.1

With respect to total cost of ownership, equipment capital costs, cost of spares, installation, maintenance, reliability and production downtime costs shall be considered as part of the evaluation.

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Availability, operability, reliability and ease of maintenance of the equipment is of paramount importance.

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The SUPPLIER shall give particular consideration to these factors and provide the following data for all equipment within the scope of their supply. Maintenance Schedule detailing: •

Interval between maintenance activities

•

Work to be carried out

•

Estimated job times/skill

•

Estimate of spares usage over a given period

•

Historical data of Mean Time Between Failure (MTBF) and Mean Time To Repair (MTTR) for main components. The SUPPLIER shall identify the critical components which affect overall reliability and make any recommendations which will maximise availability and reduce maintenance costs. 5

EQUIPMENT DESIGN AND MANUFACTURING

5.1

ELECTRICAL SYSTEM

5.1.1

The electrical arrangement of the switchgear, MCC, protection, metering, control, interlocking, autotransfer, inter-tripping, etc. shall be as shown on the switchgear one line diagram.

5.1.2

All components of the switchgear shall be rated for the electrical system characteristics shown on the one line diagram or data sheet. Special reference is made in respect of enhanced circuit making requirements and the dc component of fault current at breaking.

5.1.3

The switchgear/MCC shall be suitable for operation with system voltage and frequency variations as stated on the one line diagram or data sheet.

5.1.4

Wherever possible rated voltages and lightning impulse withstand voltages shall be selected from the standards listed and will be stated in the data sheet.

5.1.5

It is to be assumed that all outgoing circuits may be fully loaded without diversity.

5.1.6

The following busbar/ wiring phase colours shall be adopted: 3 Phase Systems :Line 1 :- Yellow Line 2 :- Green Line 3 :- Red Earth :- Green/Yellow Single Phase/Neutral (2 wire) Systems :Line:-

Red

Neutral:-

Blue

Earth:-

Green/Yellow

Direct Current Systems :Positive:-

Red

Negative:- Dark Blue Earth:-

Green/Yellow

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5.2

STRUCTURAL AND MECHANICAL REQUIREMENTS

5.2.1

Switchgear cubicles shall be metal enclosed, vermin proof, free standing, direct to floor mounting, flush fronted withdrawable type consisting of separate panels and arranged to form a single structure with a common busbar assembly. The panels shall be constructed from prime quality folded and welded sheet steel not less than 2mm thick. The design of the panels shall be such that no permanent or harmful distortion occurs either when being lifted by eye bolts or when moved into position by rollers. It shall not exceed a height of 2.5m.

5.2.2

The Switchgear/MCC shall consist of circuit breakers, motor starters, and feeder switch units, which shall be housed in separate compartments within the Switchgear/MCC. Each control compartment within the panel shall have a hinged door fastened by means of a lockable handle. The control compartment shall be fully segregated from the high voltage compartment by earthed steel. It shall be possible to close the front high voltage compartment door with the switching device in the service or earthed position.

5.2.3

All control, indication and protection equipment associated with a circuit breaker shall be accommodated in the segregated control compartment. In the event that additional space is required, a dedicated free-standing floor panel shall be provided to accommodate the additional equipment. Equipment requiring adjustment or inspection will not be located more than 1900mm from floor level.

5.2.4

Each panel shall be fully assembled and tested at the SUPPLIER’s works including busbars and wiring so that installation activities are limited to setting of panels and connecting inter-panel wiring, busbars and outgoing circuits.

5.2.5

Switchgear/MCC and busbars shall be arranged to permit future extension at either end without shutting down the switchgear until busbar connection is required. Where skeleton panels are specified, they shall be arranged so that equipping can take place without de-energising the board.

5.2.6

The structure, including doors and panels, shall be capable of withstanding the internal pressure created by faults within the structure (equal to the maximum fault-current rating) without danger to the operating personnel. The minimum standard required is detailed in IEC 60298 Appendix AA.

5.2.7

The structure shall be provided with barriers to prevent the transfer of ionised gases between compartments.

5.2.8

Structures shall be self ventilating.

5.2.9

Interlocks, busbar shutters, covers, etc. shall be provided to prevent incorrect or unsafe operation, and to prevent access to live parts.

5.2.10 Switchgear/MCCs shall be designed and constructed to facilitate inspection, cleaning, repair and maintenance and to ensure absolute safety during operation, inspection and maintenance. It shall be possible to work safely within individual compartments whilst the remainder of the Switchboard/MCC is energised. 5.2.11 Similar parts and components shall be interchangeable. 5.2.12 The overall switchgear enclosure shall as a minimum have a degree of protection IP 31 according to IEC 60529 unless specified otherwise on the data sheets. 5.3

CIRCUIT BREAKERS

5.3.1

Circuit breakers shall be withdrawable vacuum type or SF6 circuit breakers.

5.3.2

SF6 circuit breakers shall have a low pressure/ leakage alarm.

5.3.3

Circuit breakers of identical rating shall be interchangeable.

5.3.4

Circuit breakers shall be supplied with a means to manually operate the open/close mechanism, however a means shall be provided to enable the close function to be inhibited where it may be unsafe.

5.3.5

Tripping, closing, control and indication supplies for circuit breakers will be as shown on the one line diagram or data sheets and be complete with intelligent protection and control devices in

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accordance with project specification No. KE01.00.000.KD.E.SF.0005.000, Integrated Electrical Protection and Control. 5.3.6

It shall not be possible to close a circuit breaker electrically while a trip circuit is made or the tripping supply lost

5.3.7

Circuit breakers used as motor starters shall be fitted with a no volt release coil.

5.3.8

Circuit breaker operating mechanisms shall be as stated on the one line diagram or data sheet.

5.3.9

Test facilities shall be provided to permit operation of the circuit breaker whilst in the test/isolated position.

5.3.10 Circuit breakers shall be provided with trip circuit supervision to monitor trip circuit continuity and trip circuit supply. Alarm and indication facilities shall be provided for each circuit breaker and a volt free group contact provided via internal bus wiring for remote common alarm. 5.3.11 Circuit breakers shall be provided with two normally open and two normally closed spare, auxiliary contacts wired out to terminals. 5.3.12 In addition auxiliary contacts shall be provided for:•

Circuit breaker in service position.

•

Circuit breaker removed from service position.

•

Circuit earthed.

• Busbar earthed. It shall be possible to easily re-arrange contacts for normally "open" or normally "closed". 5.3.13 Withdrawable circuit breakers and their cubicles shall: a) Be interlocked to prevent •

The breaker being inserted into the service position unless it is open.

•

The breaker being inserted into the service position unless the earth switch is open.

•

The breaker being withdrawn from the service position unless it is open.

•

The breaker being closed unless it is in the service, test or fully withdrawn position.

b) Be fitted with busbar and cable circuit shutters, which shall provide a minimum degree of protection of IP20. •

With padlocking facilities.

•

Coloured red for busbar and yellow for circuit. They shall also be clearly identified in large white lettering. For bus-section and coupler applications the shutters shall also be labelled with the busbar number.

•

Of metal construction and effectively earthed to the main housing.

•

Of the positively driven type, gravity drop shutters are not acceptable.

•

Capable of being individually operated by hand.

•

Durable phase colour identification shall also be provided on a prominent position.

•

Bus bar and circuit covers shall be operated independently of each others

c) Have provisions for padlocking in the test, earthed and isolated positions and have labels to clearly indicate these positions. d) Be provided with an anti pumping facility in the circuit breaker closing circuit.

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5.4

MOTOR STARTERS

5.4.1

Motor starters shall be of one of the following types in accordance with the one line diagram and data sheet:•

Fused contactor

• Circuit breaker The break-point from contactor to circuit breaker is dependent on the voltage, contactor rated maximum continuous and breaking current, and the motor full-load and locked rotor currents. 5.4.2

Motor starters shall be direct-on-line starting unless otherwise stated. All starters shall be arranged for remote control in addition to any controls specified at the MCC.

5.4.3

Motor starters of the fused contactor type shall be withdrawable and comprise:a) Isolator - fault make, load break, mechanically interlocked with door/withdrawal mechanism, padlockable in the ‘off' position only, fitted with additional auxiliary contacts (for isolating internal/external controls, etc.) as specified on the data sheets and interlocked with contactor so that isolator cannot be opened or closed unless the contactor is in the open position. Alternatively a load break isolator (otherwise as above) is acceptable provided that the design is such that the possibility of a fault between the isolator and the fuse can be shown to be negligible. Where isolation is achieved by withdrawing the complete truck it shall conform as above and be interlocked to prevent isolation unless the contactor is in the open position. b) Fuses - main fuses shall be high rupturing capacity type, have motor protection duty characteristic and fitted with striker pins. Operation of any striker pin shall trip the contactor. The fuses shall be selected to limit the fault current to the breaking capacity of the contactor. They shall also suitable for successive starts of the motor. Control, indication and instrument protection shall be by means of MCBs. c) Contactor - suitable for uninterrupted duty, intermittent duty Class 30 and utilisation category AC3 in accordance with IEC 60632. If motor re-acceleration is required it will be specified on the one line diagram. A time delay on breaking is permitted only by an agreement with the Purchaser. d) Control Transformer - rated to suit starter control devices and any additional control and indication loads required. It shall be supplied from the load side of the main circuit fuses. e) Intelligent control and protective devices(s) affording overload, single phasing earth fault protection and other functions in accordance with project specification No. KE01.00.000.KD.E.SP.0005.000, Integrated Electrical Protection and Control. f)

The contactor shall be fitted with an operations counter as well as one normally open and one normally closed contact wired out to auxiliary contacts.

g) Additional items as specified on the one line diagram and data sheets. 5.4.4

Circuit breaker fed motor starters shall be arranged as shown on the one line diagram and generally be in accordance with the specification for high voltage metal enclosed switchgear above.

5.4.5

Motor starters shall be provided with a stop lock push button (shrouded to prevent inadvertent operation) located on the front of the starter.

5.4.6

Test facilities shall be provided to permit operation of the motor starter without energising the HV circuit.

5.4.7

Where a mechanically latched contactor is specified on the one line diagram it shall have an electrical trip coil and manual release.

5.4.8

In the event of loss of interrupting media (SF6 or vacuum) the contactor must be able to interrupt normal current at rated voltage.

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If necessary, surge protection shall be provided by the manufacturer.

5.4.10 All motor starters shall incorporate an Emergency Shutdown (ESD) Relay (preferably incorporated within the IPCD, providing the input is hard wired and not by serial link). The relay shall have its coil wound for 24V dc and be arranged such that de-energisation of the relay stops the motor. Provision shall be made for permanently shorting the relay contacts in cases where an ESD facility is not required. The coil connections of the individual relays shall be taken via suitably protected wiring to a marshalling/terminal box centrally located within the switchboard. 5.5

BUSBARS

5.5.1

The busbar system shall be fully insulated, 3 phase and rated to withstand all dynamic thermal and dielectric stresses for the full length of the switchgear and the control gear.

5.5.2

Auxiliary wiring shall not be run in the busbar compartment.

5.5.3

Busbars and connections shall be manufactured from hard drawn high conductivity electrolytic cold rolled copper. Connections between vertical droppers and the main busbars shall be made using solid bars. Flexible connections are unacceptable.

5.5.4

Busbars shall be fully epoxy insulated. Busbar insulation shall be continued as far as practicable into the circuit breaker and contactor compartment. Other types of insulation may be offered by the SUPPLIER.

5.5.5

Busbars shall be of the same cross sectional area throughout the length of the switchgear/MCC.

5.5.6

Phase busbars shall be run in a separate compartment not requiring access for any other purpose.

5.5.7

Busbars shall be marked to indicate the phase colouring as indicated in section 3.1.6.

5.5.8

Busbars, at bus section switches, shall be arranged to permit safe work on one bus whilst the other remains energised. In addition it shall not be possible for arcs to transfer across a section or coupler or it’s compartment.

5.5.9

Busbar joints and connections shall be made utilising high tensile bolts nuts and washers allowing thermal expansion and contraction without coming loose. Provision shall be made for access so that maintenance of the joints is possible without damaging the insulation and resistance measurements across the joints can be taken.

5.5.10 An earthing busbar sized for the full fault rating of the switchboard (minimum 50x6mm copper) shall be provided along the full length of the switchgear structure with provision for earth cable connections at each end. Where frame leakage protection is specified a separate insulated bus bar is required in addition. 5.5.11 Busbars and connections shall be adequately sized, braced and supported to withstand the mechanical forces and thermal effects resulting from the switchgear rated short circuit current and carry certification from a recognised testing authority. 5.6

EARTHING

5.6.1

All metallic non-current carrying parts of the switchgear/MCC shall be bonded together and connected to the switchgear earth busbar.

5.6.2

All doors shall be bonded to the main structure by means of a flexible copper connection arranged so that it cannot be trapped as the door is opened or closed.

5.6.3

Withdrawable parts (e.g. circuit breakers and motor starters) shall be effectively earthed until they are completely withdrawn with all power and control connections disconnected.

5.6.4

Provision shall be made, adjacent to the cable termination for earthing cable armouring to the earth busbar.

5.6.5

An integral earthing switch for motor feeder cables shall be provided and interlocked with the isolator or contactor truck. A visual indication shall confirm that the earth switch is engaged and closed.

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5.7

SECONDARY WIRING

5.7.1

Secondary wiring shall be 450/750 volts grade of size 1.5 mm minimum. The material of insulation shall be selected having concern for the minimum site temperature in which the equipment has to operate or may be worked upon.

5.7.2

Secondary wiring within the switchgear/MCC shall be securely held in position (either loomed or run in conduit/trunking). Where wiring passes through compartments containing high voltage apparatus then it shall be run in earthed metallic conduit/trunking without gaps, holes or joints.

5.7.3

Secondary wiring layout shall permit alterations to individual circuits without requiring shutdown of the complete switchgear/MCC.

5.7.4

Bus wires for closing, tripping, control, indication, heaters, etc. shall be run within the switchgear/MCC and individually protected.

5.7.5

Wiring identification shall be by numbered and/or lettered interlocking sleeve ferrules, of insulating material adjacent to the terminals. They shall be indelibly marked and removal without disconnecting the wire from its terminal shall not be possible.

5.7.6

Flexible cables shall be used for connections on door mounted equipment. Wiring shall be loomed, wrapped in flexible PVC conduit and be firmly clamped at both ends to prevent movement at terminations.

5.7.7

All wiring for external connections shall be brought out to individual terminals on a readily accessible terminal block.

5.7.8

No more than two wires shall be connected to a terminal. Where required, terminals shall be commoned by a proprietary copper link.

5.8

CABLE TERMINATIONS

5.8.1

Cable terminating facilities and terminals shall be suitable for the specified cable type and conductor size.

5.8.2

Terminal blocks shall be arranged and positioned to afford ready access for carrying out external cable termination, testing, inspection and maintenance. There shall be ample clear space allowed between the terminals and the gland plate for the spreading and termination of external conductors.

5.8.3

Terminal blocks shall be mounted in a single deck arrangement.

5.8.4

The panel wiring shall be on one side of the terminal block only.

5.8.5

Terminal blocks shall be shrouded or provided with fixed transparent covers. Pinch screw type terminals are not acceptable.

5.8.6

Terminals for different voltages shall be separated by partitions and labelled accordingly.

5.8.7

Terminal boxes (where specified) shall be suitable for dry type terminations with stress relieving unless otherwise specified.

5.8.8

A terminal box or chamber with undrilled gland plate or entry panel of sufficient dimensions to terminate the specified cables shall be provided. Direction of cable entry shall be as stated on the one line diagrams.

5.8.9

Positioning of cable terminations shall avoid obstruction of other cable terminations, removable covers, etc. and provide for easy access for terminating cables.

2

5.8.10 Cable supports shall be provided (where practicable) by the SUPPLIER to avoid undue strain on the cable termination. 5.8.11 Termination of single core cables shall be through a non magnetic metal panel or gland plate and provision made for bonding and earthing any armour and/or concentric ground conductors. 5.8.12 Separate cable facilities shall be provided for each switchgear or starter cubicle and for power and control cables. Project Specification - High Voltage Metal Enclosed Switchgear and Motor Control Centres

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5.9

AUXILIARY SUPPLIES

5.9.1

Circuit breaker tripping, close control and indication power will be supplied from suitably rated 110 volt dc supply units. Individual dc supplies shall be provided for each incomer including the associated feeders on that bus bar section and one dc supply for the bus section breakers. Unless otherwise specified, the bus wiring shall be designed for a maximum of any three circuits to be closed simultaneously with a control voltage of 85% of nominal at the switchboard.

5.9.2

Circuit breaker spring charging power shall be 110 volts dc supplied from an external source unless otherwise specified. Spring charge indication shall be provided.

5.9.3

All circuits must be capable of tripping simultaneously under the same conditions. Where dc supply units are not in the SUPPLIER’s scope the standing load, peak load and permissible voltage variation shall be stated. Under Voltage alarms are to be provided for each 110 volt dc supply.

5.9.4

HV Contactors shall derive 230 volt ac control power from control transformers located within each motor starter.

5.9.5

All auxiliary supplies shall be individually MCB protected within each circuit breaker housing. Double pole MCB’s are to be used for dc circuits.

5.9.6

For shunt trip circuits the protection shall be rated at least 300% of the load.

5.9.7

Anti-condensation heater supplies as specified for switchgear, starters and motors, shall be fed from a single external 230 volt ac source for each busbar section. Surface temperature of all heaters o shall not exceed 200 C.

5.9.8

Incoming Auxiliary Supplies shall be MCB protected at the point of entry to the switchboard. The SUPPLIER shall ensure proper discrimination and individual monitoring.

5.10

INSTRUMENT TRANSFORMERS

5.10.1 Voltage and current transformers of ratio, output, class and accuracy for protection and metering, shall be provided as shown on the one line diagram/ data sheet. 5.10.2 The SUPPLIER shall provide details of ratio, output, class and accuracy for all instrument transformers in his supply. 5.10.3 The secondary windings of instrument transformers shall be earthed at one point through a removable link. Provision shall be made for attaching test links. 5.10.4 Current transformers shall be bar type and rated to withstand the thermal and magnetic stresses resulting from through fault current equal to the switchgear/MCC fault rating in time and intensity. In exceptional circumstances the Purchaser may authorise the use of wound CTs where bar type cannot provide a suitable ratio. 5.10.5 Where current balance protection is specified the SUPPLIER shall provide calculations together with current transformer magnetisation curves to prove the through fault stability of the protection up to the switchgear fault rating. 5.10.6 Shorting terminals for current transformers shall be provided at the outgoing terminals where external connections are required Voltage transformers shall be located as shown on the one line diagram. Current transformers required for current balance protection schemes and not mounted within the switchgear shall be supplied loose by the SUPPLIER (unless otherwise stated). The SUPPLIER shall liase with the supplier of the equipment where these CT’s are to be fitted to agree dimensions, support details etc. 5.10.7 Voltage transformer primary winding shall be protected by High Rupturing Capacity Cartridge fuses. MCBs shall be provided on the secondary side. 5.10.8 Voltage transformers shall have provisions for safely disconnecting the fuses and transformers from the energised busbars. They shall have provision for padlocking in both the engaged and disengaged positons. The rated output of any voltage transformer shall be 50 % in excess of the burden of the connected equipment with a minimum rated output of 50 VA. Unless otherwise stated on the one line diagram voltage transformers shall have an accuracy class of 0.5.

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5.10.9 Where voltage transformers of the plug-in withdrawable type are used, shutters shall be provided to automatically seal off the high voltage spouts when voltage transformers are withdrawn 5.10.10 Instrument transformer nameplates shall be fixed in a position so that details can easily be read when fitted in the cubicle. 5.11

METERING, PROTECTION, CONTROL AND INDICATION

5.11.1 Metering, protection and control shall be provided as shown on the one line diagram or data sheet incorporated into an integrated protection and control device in accordance with specification entitled Integrated Electrical Protection and Control Specification, Document No. KE01.00.000.KD.E.SP.0005.000. Switchgear protection relays generally shall include communications features. Motor protection shall comprise an intelligent integrated motor control system providing features at least equivalent to the above along with the control and metering facilities referred to later in this specification. 5.11.2 Meters and relays shall be flush mounting and fitted on the front of the switchgear. Where conventional indicating instruments are shown on the one line diagram, they should be in accordance with IEC 60051. 5.11.3 Meters and relays shall be capable of withstanding without damage the secondary currents associated with the switchgear rated fault current flowing in the primary of current transformers in intensity and time. 5.11.4 External zero adjustment shall be possible on all indicating instruments to facilitate adjustment without dismantling the instrument. Ammeters shall be scaled in amperes such that full load corresponds to between 50 and 80% of the angular deflection. 5.11.5 Motor starters shall be provided with an ammeter having compressed overload scale of not less than six times the motor full load current. The motor full load current reading shall be between 50 - 65% of full scale deflection. The meters shall be provided with a movable red pointer for motor operating current indication and shall be scaled in amperes. 5.11.6 Protective relays shall, wherever possible, be of the draw out type with hand reset operation indicator and be fitted with test blocks. 5.11.7 Voltage free alarm contacts shall be provided for alarms as shown on the one line diagram or data sheet. 5.11.8 Indication lamps, operations counter and positive drive mechanical position indicators shall be provided for each circuit breaker. Contacts for remote indication shall be provided. Signalling lamps shall be the following colours according to IEC 60073:•

WHITE lamp - circuit breaker or contactor closed

•

RED lamp - circuit breaker or contactor tripped for protection

•

GREEN lamp - circuit breaker or contactor open ready for closing

•

AMBER lamp - alarm

5.11.9 Control of circuit breakers shall be carried out at either:•

Control Switch at Cubicle Door

•

Remote control desk/panel

5.11.10 It shall be possible to mechanically trip circuit breakers at the switchgear irrespective of service status and position. 5.11.11 Control of motors shall be carried out: •

at the MCC (emergency stop only)

•

at a remote control desk/panel (via hard wire or serial link)

•

at a control station local to the motor (Hardwired Stop, Start in conjunction with a DCS permissive signal)

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Motor running / stopped indications shall be provided on all motor starters. 5.11.12 When the circuit breaker or motor starter is in the fully withdrawn or earth position, operation shall only be possible from the switchgear/MCC. When the circuit breaker is in the test position, control shall be available from all control locations. 5.12

ANTI-CONDENSATION HEATERS

5.12.1 Thermostatically controlled heaters suitably rated to prevent condensation shall be provided within the switchgear, MCC and protection cubicles. 5.12.2 Motor anti-condensation heaters shall be controlled by auxiliary contacts on the contactor/circuit breaker. Contacts shall be arranged so that when the motor is energised the heater is off and when the motor is de-energised the heater is on. 5.13

ELECTROMAGNETIC COMPATIBILITY (EMC)

5.13.1 In order to comply with the requirements of IEC 61000 all electrical equipment shall meet the current levels of “emission” and “immunity”. All applicable equipment shall be designed so that the Electromagnetic disturbance it generates does not exceed a level allowing telecommunications equipment and other relevant apparatus to operate as intended. 5.13.2 The design of the equipment should be of an adequate standard to maintain it’s performance during it’s operational life in its installed environment. For the purpose of EMC the performance of the apparatus must comply, is taken to be degraded if permanent or temporary loss of function occurs. 5.14

MATERIALS OF CONSTRUCTION The SUPPLIER shall be responsible for the selection of materials for construction, unless otherwise specified in the data sheets or referenced Project Specifications. In selecting materials and designing the equipment, the SUPPLIER shall give special consideration to the operating and environmental conditions specified.

5.15

PAINTING AND COATING

5.15.1 The SUPPLIER’S standard finish will be acceptable subject to the following minimum standards: a) Components degreased, sprayed with a zinc phosphate primer and passivated. b) Electrostatically applied polyester powder coating to an average dry film thickness of 75 micron. 5.15.2 Finish colour shall be RAL 7035 (Grey). 5.15.3 The SUPPLIER shall submit details of the paint finish with the bid. 5.15.4 The SUPPLIER shall provide 2.5 litre of touch-up paint to repair any damage incurred during installation. 5.16

NAMEPLATES, MARKING AND LABELLING

5.16.1 Switchgear cubicles and components shall be identified by dual language (English and Russian) labels. Cubicle label designations (located at front and rear of panel) shall be in accordance with the one line diagram. All withdrawable components shall have a circuit label. A main switchboard nameplate label shall be provided. 5.16.2 A manufacturers rating plate shall be affixed in a prominent position on each switchboard/MCC giving the following information: •

Manufacturers name and type.

•

Switchboard/MCC Tag Number.

•

System voltage, phases, wires and frequency.

•

Rated fault current.

•

Busbar rating.

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•

Year of manufacture.

•

Purchaser’s name.

•

Purchaser’s Order No.

•

Order Item No.

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5.16.3 Each cubicle shall be fitted with a label giving the following information:•

Current and voltage rating.

•

Rated fault making and breaking current

•

Equipment tag number and equipment designation

5.16.4 Labels shall have black characters on a white background and be made of a non-corrodible material. Labels shall be affixed by stainless steel screws. 6

TESTING AND INSPECTION

6.1

GENERAL

6.1.1

Inspections and witnessed tests shall be as detailed in the IDS which forms part of requisition. Testing will be in accordance with IEC 60298 and any additional requirements as shown on the IDS.

6.1.2

The equipment shall be inspected and witnessed tested by the Purchaser and COMPANY at the manufacturer' s works, as described in the relevant standards and as noted below.

6.1.3

The Purchaser shall be allowed access to manufacturer' s shop and offices at all reasonable times for purposes of inspection and obtaining information on the progress of work.

6.1.4

The SUPPLIER shall submit a detailed written test procedure and programme of testing to the Purchaser in accordance with the Supplier Documentation Requirements Schedule (SDRS) prior to the commencement of the tests. Where applicable, specialist equipment SUPPLIERS shall be notified. The programme shall indicate the sequence and timing of all inspection, testing and precommissioning requirements.

6.1.5

All parts of the installation shall be inspected, tested and certified, fully in accordance with the referenced codes and standards. The Purchaser reserves the right to witness the following tests:•

Routine tests on all switchgear/components as specified in the referenced codes and standards

•

Operational (electrical and mechanical) tests on all components

•

Protection operation by primary injection of current and voltage as required

•

Interchange ability test

•

Type tests where carried out for this application

6.1.6

No witnessed testing shall take place until all the latest relevant drawings, certificates and specifications have been issued to and approved by the Purchaser.

6.1.7

The SUPPLIER shall confirm satisfactory completion of all routine tests and shop inspection prior to inspection by the Purchaser, to ensure that the witnessed testing is not prolonged by faultfinding and rectification

6.1.8

Faults or unsatisfactory operations that result in abortive witness tests shall be rectified at the expense of the SUPPLIER. Any expense incurred by the COMPANY or the Purchaser resulting from abortive tests shall be chargeable to the SUPPLIER.

6.1.9

The SUPPLIER shall submit to the Purchaser for approval a full set of standard test sheets suitable for recording all test results. Where tests are required to be carried out for which there is no standard test sheet, the SUPPLIER shall prepare suitable test sheets for approval by the Purchaser.

6.1.10 The SUPPLIER shall supply all necessary personnel, tools, tackle, test equipment and other items required to satisfactorily carry out all the tests. All instruments shall be calibrated in accordance with the manufacturer’s recommendation. Copies of the calibration certificates shall be provided with the test results. Only competent personnel shall operate test equipment. 6.1.11 Should the equipment not pass the witnessed tests, further witnessed tests may be required. The SUPPLIER shall reimburse the Purchaser and/or COMPANY for time and expenses incurred during any repeat witnessed tests.

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6.1.12 On satisfactory completion of the tests and before despatch, the SUPPLIER shall submit copies of the test certificates for approval. The equipment shall not be despatched until the Purchaser has approved the test certificates. 6.1.13 Inspection and testing documentation shall be prepared by the SUPPLIER and submitted to the Purchaser prior to works acceptance. 6.1.14 The SUPPLIER shall record all the details, measurements and data as required in the relevant standards. 6.1.15 All test results shall be written at the time of test in blue ink and signed by the tester and the witness. Alterations or corrections shall be made by crossing out not by over-writing the previous data. No test results shall be corrected with correction fluids or similar correction media. Where the SUPPLIER is unable to provide the original test certificates as described above, the tests shall be repeated at the SUPPLIER’s cost. 6.1.16 The SUPPLIER shall provide the original and a copy of the inspection and test sheets, together with any supportive documentation required in the relevant standards, to the Purchaser within five working days of the tests being carried out. 6.1.17 The inspection and test documentation shall indicate all of the test instrument details including the manufacturer, type, date of calibration, scale used and the recorded results/tolerances. 6.1.18 Following satisfactory completion of all works inspection and tests the SUPPLIER shall submit all completed certificates, results and related documents to the Purchaser for comment and/or acceptance. 6.1.19 Acceptance or acknowledgement of any test results or data by the Purchaser does not relieve the SUPPLIER of responsibility for the equipment supplied as required in the Specification, relevant Standards, Regulations or Codes of Practice. 6.2

MATERIAL CERTIFICATION Material Certification shall be provided in accordance with the Supplier Documentation Requirements Schedule (SDRS) listed in the Requisition.

7

PRESERVATION, STORAGE, HANDLING AND SHIPPING

7.1

Preservation, handling, storage and shipping of SUPPLIER equipment and materials shall comply with the requirements detailed in the requisition and associated project specification.

7.2

Unless indicated otherwise in the contract, the equipment shall be thoroughly prepared for export and packed for shipment as specified in the requisition.

7.3

Methods of shipment to be employed are subject to Purchaser approval. The SUPPLIER shall submit details of the proposed methods with the bid.

7.4

Export packing methods shall also be suitable for extended storage at the jobsite under covered shelter and in the environmental conditions detailed. For this purpose, it shall not be necessary to hook-up any anti-condensation heaters, where they are provided. Sufficient drying agent shall be provided inside the packing to absorb any possible condensation products.

7.5

Where the storage period is expected to exceed 6-months, the Purchaser will notify SUPPLIER and arrange for possible additional protection and inspection by manufacturer' s representatives.

7.6

Marking of shipping containers shall be subject to Purchaser approval, and guidelines for special marking shall be followed meticulously, to ensure positive identification at the jobsite.

7.7

During transportation, shipment, storage and installation all openings shall be sealed weather-tight.

7.8

The SUPPLIER shall separately pack any miscellaneous equipment that must be removed for shipment.

8

WEIGHT

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SUPPLIER shall provide shipping, installation, operation and maintenance weights including centre of gravity. 9

INSTALLATION, SITE TESTING AND COMMISSIONING

9.1

SUPPLIER shall provide full details for installing, site testing, commissioning and start up of the equipment as specified in the ‘Supplier Documentation Requirements Schedule (SDRS)’ listed in the Requisition.

9.2

When specified in the Purchase Order, the SUPPLIER shall provide representatives to assist the Purchaser during installation, commissioning and initial start-up of the equipment.

9.3

SUPPLIER shall identify any specialised training required for COMPANY’s operations and maintenance personnel.

10

MAINTENANCE REQUIREMENTS

10.1

SUPPLIER shall provide full details for maintaining the equipment as specified in the ‘Supplier Documentation Requirements Schedule (SDRS)’ listed in the Requisition.

10.2

Due consideration shall be given for easy accessibility to all the items, for maintenance and operational requirements, when designing the internal layout of the equipment. Access shall be provided to all equipment and any area requiring maintenance. The equipment shall be designed so that all maintenance can be carried out with the minimum special facilities/tools.

10.3

All switchboards shall be provided with horizontal and vertical alignment bolts and shall be supported on stainless steel shims at each mounting point to facilitate re-alignment at a later stage. No tapered shims are allowed. Sufficient quantity of pre-cut shims shall be provided loose for site commissioning.

10.4

SUPPLIER shall provide in their bid, maintenance lifting requirements for the switchboard, and advise suitable lifting method. eg. Runway beam, overhead travelling crane

11

SPARE PARTS AND SPECIAL TOOLS

11.1

SPARE PARTS

11.1.1 The SUPPLIER shall provide itemised and priced recommended spare parts and consumable lists as follows for : •

Installation and commissioning

•

First two years of operation

•

Insurance / Capital spares

•

Parts to be replaced because of their operating life limitations

11.1.2 Installation and commissioning spare parts for all equipment supplied shall be included as part of the equipment scope of supply 11.1.3 After the award of Purchase Order, the Supplier shall complete and submit the Spare Parts Interchangeability List (SPIL) provided by the Purchaser. 11.2

SPECIAL TOOLS

11.2.1 All special tools and equipment necessary for the installation, maintenance and overhaul of the equipment, including any required maintenance lifting equipment, shall be supplied 11.2.2 The special tools shall be delivered in a lockable steel cabinet together with the main equipment 11.2.3 The equipment Installation, Operation and Maintenance Manuals shall include a list of special tools for equipment maintenance and instructions on how to use them. 12

DOCUMENTATION

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12.1

SUPPLIER shall provide the documentation detailed in the ‘Supplier Documentation Requirements Schedule (SDRS)’ and the ‘Supplier Documentation Descriptions’ as listed in the Requisition.

12.2

Documentation shall be provided in accordance with the Supplier Documentation Instructions as listed in the Requisition.

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