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Electrical Engineering Specification Category
Fault Protection Title
Protection System Requirements for the High Voltage Network Reference Number
EP 19 00 00 02 SP Version
3.4 Date of Issue
JUNE 2007 Status
Approved
Copy No.
A coloured number in this space indicates that this document is controlled
Electrical Engineering Standard Fault Protection Protection System Requirements for the High Voltage Network
EP 19 00 00 02 SP
DISCLAIMER RailCorp has used its best endeavours to ensure that the content, layout and text of this document are accurate, complete and suitable for it’s stated purpose. It makes no warranties, express or implied, that compliance with the contents of this document shall be sufficient to ensure safe systems of work or operation. RailCorp will not be liable to pay compensation in respect of the content or subsequent use of this document for any other purpose than its stated purpose or for any purpose other than that for which it was prepared except where it can be shown to have acted in bad faith or there has been wilful default. DOCUMENT APPROVAL The technical content of this document has been approved by the relevant RailCorp engineering authority and has also been endorsed by the RailCorp Configuration Management Committee directly or as delegated through the conditions of the Configuration Management Policy. DOCUMENT SUPPLY and CONTROL The Primary Version of this document is the electronic version that is available and accessible on the RailCorp Internet and Intranet website. It is the document user’s sole responsibility to ensure that copies are checked for currency against the Primary Version prior to its use. The approving section does not make controlled copies of this document available by any means other than on the aforementioned website. Controlled hardcopy versions of this document may be made if they are registered using a local document management and distribution system. When controlled hardcopy versions are issued using a local document management system each copy is to be uniquely identified in the Control Box provided on the front of the document. The identifier used must identify the local distribution centre and the copy number. The identifier is to be marked using a colour other than black or grey. COPYRIGHT The information in this document is Copyright protected. Apart from the reproduction without alteration of this document for personal use, non-profit purposes or for any fair dealing as permitted under the Copyright Act 1968, no part of this document may be reproduced, altered, stored or transmitted by any person without the prior written consent of RailCorp.
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About This Standard This document covers the Protection System requirements for the RailCorp High Voltage AC Network for 11kV, 33kV, 66kV and 132kV system voltages. The scope of this publication does not currently include specific requirements for the high voltage AC network at 2kV. This will be incorporated in a future revision of this specification. This document does not include protection requirements for the 1500V DC system. The Specific Protection Equipment Requirements (Section 5 and associated Appendix) are common requirements for the entire high voltage network. These protection requirements cover general design principles for protection schemes, as well as requirements relating specifically to the protection equipment. They do not include equipment used for detection and measurement of non-electrical protection parameters (such as oil and gas sudden pressure change, fibre optic temperature measurement), other than to specify necessary interface details. The correct design, implementation and management of the overall protection system are critical to the safe and reliable operation of the RailCorp power system. As such, all design processes for the protection system must follow the RailCorp Engineering Design Management Procedures. All new installations, modified and refurbished existing installations must comply with the requirements in this document. High voltage protection systems existing at the date of release of this document are not affected by the requirements of this document.
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Version History Version 2.0 The changes in this document are: •
Reformatting of the document
•
Changes to organisational names and position titles to reflect the formation of Rail Infrastructure Corporation
Version 3.0 •
Major expansion of information in the previous version.
Version 3.1 •
Correction to pilot wire relay model.
•
Transformer differential relay types modified.
•
Alternative busbar fault detection system added.
•
Details of equipment connected to ACCB trip coils added.
•
33kV bus-zone CT ratio changed.
Version 3.2 •
Organisation change from Rail Infrastructure Corporation to RailCorp.
•
Clarifications to breaker fail operation implementation with pilot wire schemes.
•
Auto reclose policy for high voltage feeders added.
•
Details of earth fault operation added for rectifier transformer protection and clarification to associated trip coil operation.
•
Details of requirements when there are two battery systems and typical auxiliary supply to HV ACCB’s added.
•
MTM relay requirements added.
•
Siemens 7D6S10 pilot wire relay added as an approved relay.
•
Details of MBCI02 relay added.
•
Detailed listing of SCADA alarms added.
•
Additional protection relay identifications added.
•
Standard test block configuration amended and standard relay input and output configuration added.
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Version 3.3 •
Requirement for TCS to be fitted to existing equipment added when new protection schemes are interfacing with existing switchgear.
•
11kV feeder protection requirements added.
•
Requirements for breaker fail implementation added when installing electronic protection relays in an existing substation.
•
Details of requirements for the VT supply to protection relays added.
•
Requirements for “CLOSE INHIBIT” amended.
•
Protection and auxiliary relay labelling guidelines added.
•
Details of protection requirements for use on 11kV distribution transformers (up to 800kVA) added.
•
Correction made to P127 output relays for system transformers and rectifier transformers.
•
P632 output relay functions amended.
•
Details of test block and relay configuration added for Siemens 7SD610 relay.
•
Details of test block and configuration added for VIP35 relay.
•
Details of SCADA alarms and control that are required to be hard wired added to Appendix K.
Version 3.4 •
Requirement for position of EARTH SWITCH, DISCONNECTOR & ACCB to be supplied as an input to P127relays removed.
•
Breaker fail implementation added when a dedicated ACCB is not available.
•
Standard current transformer configuration diagrams added as an appendix.
•
Transducer model numbers detailed for 1A and 5A current transformers and voltage transducer model number expanded.
•
Details of test block and configuration added for VIP300LL relay
•
Protection requirement for 11kV equipment modified.
•
Specific protection documentation requirements added.
•
ECRL protection no-compliances added as an appendix.
•
Current transformers for 11kV switchboards added.
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Contents 1
Scope and Application .................................................................... 10
2
Normative References..................................................................... 11 2.1
International Standards.............................................................................. 11
2.2
Australian Standards.................................................................................. 11
2.3
RailCorp Documents .................................................................................. 11
2.4
Industry Publications ................................................................................. 12
3
Definitions and Abbreviations ........................................................ 13
4
General Protection Philosophy ...................................................... 15 4.1
General ........................................................................................................ 15
4.2
Protection Settings..................................................................................... 15
4.3
Grading ........................................................................................................ 15
5
Specific Protection Equipment Requirements .............................. 17 5.1
Protection Equipment Design Principles - All New HV Switchgear ....... 17
5.2
Interfacing New Protection Schemes With Existing Equipment ............ 18
5.2.1
Multiple Use of Current Transformers
18
5.2.2
Trip Circuit Supervision
18
5.2.3
Breaker Fail
18
5.2.4
Inter-trip
18
5.3
Current Transformers (CT) ........................................................................ 18
5.3.1
General Requirements
5.3.2
Additional Requirements for CT’s with a Rated Secondary Current of 1 Amp.19
5.3.3
Multiple Ratio Current Transformers
20
5.3.4
Protection Current Transformers
20
5.3.5
Measurement Current Transformers
20
5.3.6
Current Transformer Secondary Wiring
20
5.4
18
Voltage Transformers................................................................................. 21
5.4.1
General Requirements
21
5.4.2
Voltage Transformer Secondary Wiring
22
5.4.3
Voltage Transformer Alarms
22
5.4.4
Voltage Transformer Supply to Protection Relays
22
5.5
Auxiliary Supply (DC) ................................................................................. 22
5.5.1
General Requirements
22
5.5.2
Requirement for Two battery Systems
23
5.6
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Protection Relays ....................................................................................... 24
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5.7
Close Inhibit ................................................................................................ 24
5.8
Protection Alarms....................................................................................... 24
5.9
Inter-Trip Arrangements............................................................................. 25
5.9.1
Preferred Technology
25
5.9.2
Fibre Optic Pilots
25
5.9.3
Copper Pilots
25
5.10
6
Integrated Support System........................................................................ 25
Specific Equipment Applications ................................................... 26 6.1
33kV & 66kV Feeders.................................................................................. 26
6.1.1
Standard Protection Schemes
26
6.1.2
Primary Protection
26
6.1.3
Backup protection
26
6.1.4
Circuit Breaker Fail Scheme
27
6.1.5
Location of Current Transformers
27
6.1.6
Metering Requirements
27
6.2
11kV feeders................................................................................................ 28
6.2.1
Standard Protection Schemes
28
6.2.2
Primary Protection
28
6.2.3
Backup protection
28
6.2.4
Circuit Breaker Fail Scheme
29
6.2.5
Location of Current Transformers
29
6.2.6
Metering Requirements
29
6.3
High Voltage Busbars & Bus-Tie Cables.................................................. 29
6.3.1
Primary Protection for Busbars
29
6.3.2
Primary Protection for Bus-tie Cables
30
6.3.3
Backup Protection
30
6.3.4
Location of Current Transformers
30
6.4
Rectifier Transformer and Power Cubicle ................................................ 31
6.4.1
Primary Protection
31
6.4.2
Backup Protection
31
6.4.3
Circuit Breaker Fail Scheme
31
6.4.4
Protection Interface Requirements
32
6.5
System Transformers................................................................................. 32
6.5.1
Standard Protection Schemes
32
6.5.2
Primary Protection
32
6.5.3
Backup Protection
32
6.5.4
Circuit Breaker Fail Scheme
32
6.5.5
Neutral Leakage
32
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6.5.6
Buchholz Relay
33
6.5.7
Location of Current Transformers
33
6.6
11kV/415V Transformers............................................................................ 33
6.6.1
Transformers Supplied from Ring Main Units
33
6.6.2
Transformers Supplied from SCADA Controlled ACCB’s
33
6.6.3
Standard Protection Schemes
33
6.6.4
Primary Protection
34
6.6.5
Backup Protection
34
6.6.6
Circuit Breaker Fail Scheme
34
6.7
DOCUMENTATION REQUIREMENTS........................................................ 34
6.7.1
Concept Design Documentation
34
6.7.2
Detail Design Documentation
35
6.7.3
Commissioning Documentation
35
Appendix A
Protection Relays ............................................................................ 37
Appendix A.1 Approved Protection Relays...................................................................... 37 Appendix A.2 Location of Protection Relays ................................................................... 38
Appendix B
ACCB Trip Coils - Standard Equipment Connection .................... 39
Appendix C
Two Battery Systems (125V DC) - Standard Protection Equipment Connection ....................................................................................... 41
Appendix D
Interfacing With Existing Pilot Wire Schemes............................... 42
Appendix E
Current Transformers (33kV & 66kV) ............................................. 43
Appendix E.1 Rectifier Instantaneous Overcurrent & Earth Fault ................................. 44 Appendix E.2 Overcurrent and Earth Fault ...................................................................... 45 Appendix E.3 Pilot Wire Schemes .................................................................................... 46 Appendix E.4 Bus-Zone Schemes & Transformer Differential....................................... 47
Appendix F
Current Transformers for 11kV Switchgear................................... 48
Appendix G
Protection Relay Identification ....................................................... 49
Appendix H
Standard Test Block Wiring & Input/Output Relay Configuration50
Appendix I
Voltage and Current Transducers .................................................. 67
Appendix J
Pilot Wire Schemes ......................................................................... 68
Appendix K
Auto Re-close on High Voltage Feeders........................................ 69
Appendix L
Protection SCADA Alarms .............................................................. 70
Appendix M
Implementation Of SCADA Alarms & Control ............................... 74
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Appendix N
Typical ACCB Auxiliary Supply Arrangement............................... 75
Appendix O
Protection Relay Labelling Guidelines .......................................... 77
Appendix P
Standard Current Transformer Configurations............................. 81
Appendix Q
Protection Non-Compliances Particular to the ECRL Project...... 85
Appendix Q.1 11kV Protection........................................................................................... 85 Appendix Q.2 33kV Protection........................................................................................... 85
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Scope and Application This document covers the Protection System requirements for the RailCorp High Voltage AC Network for 33kV, 66kV and 132kV system voltages. The scope of this publication does not currently include specific protection scheme requirements for the high voltage AC network at 2kV system voltage. This will be incorporated in a future revision of this specification. This document does not include protection requirements for the 1500V DC system. The Specific Protection Equipment Requirements (Section 5 and associated Appendix) are common requirements for the entire high voltage network. These protection requirements cover general design principles for protection schemes, as well as requirements relating specifically to the protection equipment. They do not include equipment used for detection and measurement of non-electrical protection parameters (such as oil and gas sudden pressure change, fibre optic temperature measurement), other than to specify necessary interface details. The correct design, implementation and management of the overall protection system are critical to the safe and reliable operation of the RailCorp power system. As such, all design processes for the protection system must follow the RailCorp Engineering Design Management Procedures. All new installations, modified and refurbished existing installations must comply with the requirements in this document. High voltage protection systems existing at the date of release of this document are not affected by the requirements of this document.
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Normative References The following documents are either referenced in this standard or can provide further information. The edition is current at the time of publication of this document.
2.1
2.2
2.3
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International Standards Standard
Title
IEEE C.37.2 - 1996
Standard electrical power system device function numbers and contact designations.
Australian Standards Standard
Title
AS1102-1996
Graphical symbols for diagrams. Switchgear, control gear and protective devices.
AS 1675 - 1986
Current Transformers – Measurement and Protection
AS 2067 - 1984
Switchgear assemblies and ancillary equipment for alternating voltages above 1 kV
AS 1243 - 1982
Voltage Transformers for Measurement and Protection
RailCorp Documents Document
Title
EP 00 00 00 01 TI
RAC Electrical system General Description
EP 00 00 00 12 SP
Electrical Power Equipment – Integrated Support Requirements
EP 00 00 00 13 SP
Electrical Power Equipment – Design Ranges of Ambient Conditions
EP 00 00 00 15 SP
Common requirements for Electrical Power Equipment
EP 00 00 00 00 MP
Electric Power Technical Maintenance Plan
EP 03 02 00 01 SP
Controls and Protection for Rectification Equipment
EP 99 00 00 02 SP
System Commissioning tests
EP 01 00 00 01 SP
33kV AC Indoor Switchgear – Non-Withdrawable
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Document
Title
TS 34 10 03 01 SP
Design & Installation – Tunnel Fire safety – New Passenger Railway Tunnels
ED0001 P –ED0021 P inclusive
Engineering Design Management Procedures
Industry Publications Network Protection & Automation Guide (AREVA) (previously titled: Protective Relays Application Guide) Alstom/Areva Protection Relay Application Guides
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Definitions and Abbreviations
Abbreviation
Definition
ACCB
Alternating current circuit breaker
DC Auxiliary Supply
Supply for the operation of electronic protection relays, energisation of multi-trip relay coils, energisation of HV ACCB trip and close coils and general control circuit operations. Nominally 125V DC or 48V DC.
CT(s)
Current Transformer(s)
DC
Direct Current
Dedicated Pilot Cable
A communication cable that is used only for the control, indication and pilot wire functions between two substations. The cable is continuous between substations.
FAT
Factory acceptance test
IT
Inter-trip
Low Voltage Compartment
The compartment on the high voltage switchgear where the protection relays, control equipment and wiring is installed. The compartment is usually accessed by a hinged door and does not require any isolation or operation of the switchgear for safe access.
MTA
Protection relay used for the multi-tripping of ACCB’s. This is a automatically reset relay with a hand reset flag.
MTM
Protection relay used for the multi-tripping of ACCB’s. This is a manually reset relay with a hand reset flag.
Substation
The following are locations within the RailCorp electrical network which are classified as system substations for the purpose of this document. Any location that includes a high voltage circuit breaker. Traction substation High voltage switching station High voltage switchroom (except 2kV) 2kV locations, pole top and other distribution
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substations that use HV fuses for protection are not classed as system substations.
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RTU
Remote Terminal Unit (Interface to SCADA system)
SCADA
Supervisory Control and Data Acquisition system.
Supervisory
A connection to the Electrical Operating Centre to allow the remote operation of equipment and provision for remote monitoring of status and alarms using a SCADA system.
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General Protection Philosophy 4.1
General In designing the protection schemes for RailCorp’s high voltage network, the following general principles shall be applied:
4.2
4.3
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•
All high voltage faults shall be detected and able to be cleared by two independent sets of protection (primary and backup). Either may be circuit breakers or fuses.
•
The primary and backup protection schemes shall be independent. All HV circuit breakers shall be equipped with dual trip coils.
•
Where primary and backup protection is installed in the same substation, that substation shall have two battery systems. Some substations are exempt from this requirement. This exemption is based on risk exposure considering safety, operational impact, economic and environmental considerations.
•
The thermal limit current of the CT’s shall not constrain the rating of associated power system elements.
•
Primary protection shall be implemented using unit schemes wherever practical.
•
The protection schemes shall be designed to eliminate or manage “blind spots”.
Protection Settings •
The protection shall be set to operate at not more than 2/3 of the minimum phase to phase fault and not more than 2/3 of the minimum earth fault.
•
The overcurrent protection settings shall, as far as practicable, be at least 1.5 times the maximum load current.
•
Fault clearing times shall be minimised.
Grading •
The protection shall be graded to ensure that the fault is cleared by the protection closest to the fault, and the area of interruption is minimised.
•
A 0.3 second grading margin shall be provided for protection ‘in series’ except that breaker fail timers shall be 0.2 second.
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Relay settings shall be, as far as practicable, at least 1.5 times the highest downstream setting.
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Specific Protection Equipment Requirements 5.1
Protection Equipment Design Principles - All New HV Switchgear To ensure the independence and integrity of protection schemes the following principles shall apply: •
Protection current transformers shall be connected to protection equipment only. Approved transducers used for interfacing with the SCADA are to be regarded as protection equipment. Appendix I lists approved transducers.
•
Primary and backup protection schemes shall be implemented using separate relays.
•
Where the primary and backup scheme trip the same HV circuit breaker, the following shall apply:
•
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•
The primary and backup schemes shall use separate trip coils, one trip coil for the primary scheme the second trip coil for the backup scheme. Refer to Appendix B for standard trip coil arrangements and Appendix N for typical HV switchboard arrangements.
•
The backup scheme (protection relay, trip coil control and supply) shall have a separate auxiliary supply.
Where two DC auxiliary supplies are required (see clause 5.5) the primary protection scheme is to be supplied by battery A and the backup protection scheme supplied by battery B. •
SCADA monitored trip circuit supply supervision with local indication shall be provided for all tripping circuits.
•
The auxiliary supply for each bus-zone protection scheme (protection and multi-trip relays) shall have its auxiliary supply from a dedicated circuit originating at the distribution board. Fuse protection and monitoring shall be provided with the monitoring relay connected to the SCADA system.
•
Individual protection schemes to be connected to dedicated current transformers.
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5.2
Interfacing New Protection Schemes With Existing Equipment
5.2.1
Multiple Use of Current Transformers It is acceptable to have more than one protection scheme (maximum two schemes) connected to the same set of CT’s as long as the following applies:
5.2.2
•
It is not economically feasible to install additional CT’s (eg. Circuit breaker would have to be replaced; additional post type CT’s would be required.)
•
The protection schemes are not the primary and backup protection for the same equipment.
•
A failure of the CT’s will not result in a piece of equipment having no protection due to an existing compromise in the protection system.
•
The output of the current transformers shall be sufficient for the burden of all the connected protection schemes and associated equipment to ensure each scheme operates as required up to the available fault level.
Trip Circuit Supervision Where a new protection scheme is interfacing with existing switchgear that does not have trip circuit supervision (TCS), TCS shall be implemented either as a function of the protection relay (if available) or installation of a dedicated TCS relay (refer Appendix A).
5.2.3
Breaker Fail When new protection relays that have breaker fail functionality are installed in an existing substation, the breaker fail detection shall result in the energising of a multi trip relay. The multi-trip relay shall trip all the associated ACCB’s on the busbar.
5.2.4
Inter-trip If the breaker fail function is associated with a feeder that does not have a dedicated ACCB, then it is acceptable to implement an inter-trip by destabilising the pilot wire schemes of feeders that are a possible source of fault current. When destabilising the pilot wire schemes this must be implemented at the pilot wire relay.
5.3
Current Transformers (CT)
5.3.1
General Requirements All protection and metering CT’s shall comply with AS 1675.
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The CT shall be easily replaceable and shall be installed with polarity markings assuming supply from the bus in all cases. All secondary leads shall be terminated in individual links in the appropriate compartment where the CT is installed and the earth point formed by using a proprietary cross connection for the links being used. The CT’s shall be earthed at one point. This single point earth is to be within the applicable LV compartment. CT’s shall be rigidly clamped to prevent movement under short circuit conditions. They shall be provided with rating plates and terminal markings as specified in AS 1675. The rating plates shall be mounted in such a manner that they are visible, and the secondary terminals shall be readily accessible. Duplicate rating plates shall be mounted in the instrument compartment with connection diagram. The majority of existing CT’s installed in the RailCorp’s system have a rated secondary current of 5A. With the installation of GIS switchgear, the reduced space available for CT’s has resulted in the necessity to install CT’s with a rated secondary current of 1A. CT’s shall safely withstand the mechanical and thermal stresses set up by a short circuit equal to the full short circuit rating of the switchgear. CT’s shall have a minimum thermal limit current at least 1.5 times rated current unless modified by the RFT for the specific location. See 6.1.5 for CT location requirements for 33 & 66kV Feeders. See 6.2.5 for CT location requirements for 11kV Feeders. See 6.3.4 for CT location requirements for HV Busbars and Bus-Ties. See 6.5.7 for CT location requirements for System Transformers. 5.3.2
Additional Requirements for CT’s with a Rated Secondary Current of 1 Amp. If it is proposed to use CT’s with a rated secondary current of 1A, then the following issues shall be complied with.
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•
Provision of a detailed design solution for the secondary wiring under system fault conditions. This design solution must address the voltage withstand ratings of all connected equipment as the secondary voltages developed are five times larger than if the CT’s have the preferred value of 5A.
•
A complete integrated system support analysis of using the non-standard protection equipment must be economically justified. See 5.10 Integrated Support System for details.
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Multiple Ratio Current Transformers Where multiple ratio CT’s are used, the links associated with changing the CT ratio shall be fit for purpose. The CT terminals shall be clearly marked to enable correct changing of the ratio. The associated rating plate shall also be marked with the information to enable correct changing of the ratio.
5.3.4
Protection Current Transformers Protection CT shall be of a class entirely suitable for the connected equipment so as to give correct operation under all service and fault conditions. The following composite error shall apply: •
Differential schemes – 2.5%
•
Overcurrent & earth fault – 10%
The rated short-time is 3 seconds. The rated short time current shall have a minimum rating equal to the short time withstand current of the associated switchboard or circuit breaker. Appendix B has a table listing the typical ratio and designation of current transformers, which are preferred for use in the RailCorp electrical network. 5.3.5
Measurement Current Transformers Measurement CT’s shall be of a class entirely suitable for the application as specified in AS 1675. As a general guide the following are typical class of accuracy used in the RailCorp network: •
0.5M for general tariff metering such as supplies to shops, workshops etc.
•
2M for general measurement such as transducers and ammeters.
The measurement current transformers shall have the same ratio and thermal current limit as the associated protection CT’s on the circuit. 5.3.6
Current Transformer Secondary Wiring All CT secondary wiring shall be provided with test links at the marshalling strip within the respective low voltage compartment. The test links shall be Weidmuller SAKC10. The wiring shall be connected to the associated protection relay (or meter) via a test block that allows isolation of the relay / metering and short-circuiting of the
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current transformer secondary. If the relay test blocks are not integral with the relay enclosure, test blocks of the type Areva MMLG01 shall be provided. The test blocks shall be located adjacent to the respective protection relay. The current transformer secondary wiring shall be coloured as detailed below: •
A∅ : red
•
B∅ : white
•
C∅ : blue
•
Neutral : black
The wiring shall be a minimum size of 2.5mm2 and have an insulation rating of 0.6/1 kV. Where 2.5mm2 wiring is used it shall have a stranding of 50/0.25mm. All wiring connections to CT’s and to protection relays shall be made using double grip ring type pre-insulated crimp lugs. Wiring identification shall be in accordance with AS2067. Refer to EP 00 00 00 15 SP Common Requirements for Electrical Power Equipment, for details of cable identification requirements.
5.4
Voltage Transformers
5.4.1
General Requirements Voltage transformers shall be provided for all three phases and can either be a 3 phase voltage transformer or 3 single phase voltage transformers. Voltage transformers shall be manufactured and tested in accordance with AS 1243. They shall have a rated primary voltage as specified by the switchgear and have two secondary windings with a voltage factor of 1.9 for 30 seconds as follows:
PERFORMANCE CATEGORY
RATED VOLTAGE
ACCURACY CLASS
RATED BURDEN
A
110 V
5P
8 mS
B (residual)
110/√3 V
3R
8 mS
TABLE 2: Voltage Transformer Specifications The neutral point of the star connected primary shall be earthed. The neutral point of the star connected secondary winding shall be brought out and
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connected to suitably insulated terminals located in the LV compartment and earthed. The voltage transformers shall be protected by suitably rated circuit breakers connected in the low voltage circuit as close as possible to the transformer terminals. High voltage fuse protection of VT’s is not mandatory and is only required where necessitated by equipment design. The requirement for a residual winding is dependent on the type of protection relays to be used. For maintenance, and for the commissioning of protection relays, it shall be possible to simulate the voltage conditions that would occur during earth faults and the supplier shall explain how this is achieved. A typical way to achieve this is to remove the high-voltage fuse in any one phase and earth that phase of the voltage transformer. 5.4.2
Voltage Transformer Secondary Wiring The voltage transformer secondary wiring shall be coloured as per the current transformer wiring with the exception of any open delta wiring, which shall be purple. Terminal blocks for VT secondary wiring shall provide 4mm sockets for the connection of test equipment.
5.4.3
Voltage Transformer Alarms A three phase, phase failure relay shall be connected to the star connected secondary winding of the voltage transformer. The phase failure relay shall provide a normally closed 'VOLTAGE TRANSFORMER FAIL' alarm contact as well as visual indication. The relay shall detect both under-voltage and negative phase sequence voltage unbalance on the load side of the main circuit breaker.
5.4.4
Voltage Transformer Supply to Protection Relays The VT supply to protection relays shall be via a dedicated circuit breaker for each protection relay. The circuit breaker shall have a voltage free auxiliary contact which is connected to the SCADA system to give an “FEEDER XXX DIRECTIONAL VOLTAGE FAIL' alarm.
5.5
Auxiliary Supply (DC)
5.5.1
General Requirements The following are general requirements for the arrangement of auxiliary supplies to protection circuits and ACCB control.
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All ACCB’s shall be individually supplied from the 125V DC or 48V DC distribution board(s). The majority of RailCorp locations have an auxiliary supply of 125V DC, other locations have a supply of 48V DC. In each ACCB, distinct control circuits and equipment shall be individually fused. The fuses shall be sized to ensure there is discrimination. The following is a list of typical ACCB circuits and equipment that would be individually protected by fuses.
5.5.2
•
electronic protection relays
•
trip coil circuits
•
close control circuit
•
motor/spring charge circuits
•
alarm & indication circuits
•
DC/DC power supplies (eg. ILIS power supply, transducer supplies)
Requirement for Two battery Systems To ensure integrity of the RailCorp electrical network is maintained when an auxiliary supply fails, strategic substations are required to have two independent substation battery systems. The criteria determining this requirement are:
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Connectivity of the substation (4 or more high voltage feeders) within the RailCorp electrical network.
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Maximum high voltage fault level and the margin to the rated short-time withstand current capacity of the switchgear installed at the substation.
•
Criticality of the substation within the rail system. (eg. Main supply substation for city circle, rail tunnel, rail junction, last traction substation on a radial rail line).
•
Where primary and backup protection is installed in the same substation, that substation shall have two battery systems. Some substations are exempt from this requirement. This exemption is based on risk exposure considering safety, operational impact, economic and environmental considerations.
•
Complexity of the protection schemes and any resulting compromises in the protection coordination.
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The associated main distribution boards of the battery systems are to be capable of being paralleled. Refer to Section 5.1 and Appendix C for specific requirements relating to protection schemes when there are two auxiliary supplies at a substation.
5.6
Protection Relays All protection relays shall be flush mount and withdrawable. The auxiliary supply to the protection relays shall be 125V DC or 48V DC as determined by the existing substation battery or specified in the Substation design. Appendix A has a table listing the protection relays which are currently approved for use in the RailCorp electrical network. When specifying the type of protection relay to be used consideration must be given to ensure adequate integrated system support including availability of system spares. See 5.3.2 Additional Requirements for CT’s with a Rated Secondary Current of 1 Amp. Alternatives to relays specified in Appendix A must be approved by the Chief Engineer, Electrical Systems.
5.7
Close Inhibit Where a protection operation results in an MTM relay being energised, the MTM relay shall have normally closed contacts in the closing circuit of all the HV ACCB’s that were tripped by the MTM. This is to prevent the ACCB’s from being closed. This is applicable for all protection schemes. System transformers and 11kV/415V transformers shall have a close inhibit contact in both the primary and secondary ACCB closing circuits where fitted.
5.8
Protection Alarms Every operation of a protection relay shall result in an individual alarm being sent to the SCADA system and provide a local indication. The alarm shall enable the Electrical System Operators to accurately identify the protection scheme that has operated. If a protection relay has more than one function (eg A∅ and C∅ overcurrent elements), then where practical each function shall have a separate alarm output. Refer to Appendix L for a detailed listing of SCADA alarms.
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5.9
Inter-Trip Arrangements
5.9.1
Preferred Technology
EP 19 00 00 02 SP
Optical fibre pilots are preferred for inter-tripping. Refer to Appendix A for protection relays currently preferred for use in the RailCorp Electrical Network for type of inter-trip relay. 5.9.2
Fibre Optic Pilots Where fibre optic pilots are available, the inter-tripping may be achieved utilising pilot wire relays that have inter-tripping as a function of the relay.
5.9.3
Copper Pilots Where inter-trip arrangements are required for a feeder, it is preferred the intertrip scheme is implemented using a dedicated pair of pilots for the scheme. If there are no spare pilots in the existing pilot cable, the inter-trip may be achieved by manipulating the feeder pilot wire scheme. A minimum of 15kV isolation shall be provided to avoid transfer of voltages across the pilots. This may be achieved by using an inter-trip relay that provides isolation at either end of the scheme.
5.10
Integrated Support System An Integrated Support System exists for protection equipment. This current system is based on 5 Amp CT’s and protection relays nominated in Appendix A. An economically justified integrated support analysis is required for any proposal to use non preferred schemes, relays or CT’s. The analysis shall include relevant requirements of EP 00 00 00 12 SP and take account of the following:
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Test and support equipment
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Relay programming software
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Staff training
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Spares analysis and procurement
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Maintenance requirements analysis
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Operation and maintenance manuals
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6
EP 19 00 00 02 SP
Specific Equipment Applications 6.1
33kV & 66kV Feeders
6.1.1
Standard Protection Schemes The following schemes shall be provided for the protection of 33kV and 66kV feeders:
Primary Protection
RailCorp network feeder
Bulk Supply Feeder
Pilot wire
Directional over-current and earth fault (looking towards supply point) and Pilot wire or Distance protection (zone 1, last 20% Zone 2) at the supply end
Backup Protection
over-current and earth fault
In accordance with the other Network Operator’s policy
(may be directional if required by system configuration to achieve discrimination) and circuit breaker fail TABLE 2: 33kV & 66kV Feeder Protection Schemes 6.1.2
Primary Protection If the pilot circuit is not run via a dedicated pilot cable, an instantaneous overcurrent and earth fault check relay shall be provided in series with the trip from the pilot wire relay to prevent nuisance tripping of the feeder. All pilot wire schemes shall include pilot circuit supervision. This may be implemented either as a function of the pilot wire relay or using dedicated pilot circuit supervision equipment.
6.1.3
Backup protection The unit protection on the feeder shall be backed up by an over-current and earth fault scheme. This scheme shall operate via a circuit breaker and current transformers that are not part of the primary scheme.
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6.1.4
EP 19 00 00 02 SP
Circuit Breaker Fail Scheme The failure of a circuit breaker to open in response to a protection trip command shall be detected and the appropriate upstream circuit breaker(s) tripped. A time delay shall be provided to avoid nuisance tripping. It is preferred that the feeder pilot wire relay provides this function. Where the pilot wire relay does not have this function an overcurrent and earth fault relay (with directional capabilities) shall be provided to implement the breaker fail scheme. A contact from the pilot wire relay shall be connected to the overcurrent and earth fault relay, which will initiate an internal timer (nominally set to 0.2s). If the fault has not been cleared within this time all possible sources of supply shall their ACCB’s tripped. All ACCB’s on the same busbar section as the failed ACCB shall be tripped via a multi-trip relay. Where the operation of a breaker fail scheme shall cause a Supply Point feeder to be not available, the associated protection relay(s) shall attempt to trip the ACCB via all available trip coils. The trip coils shall be connected to separate output contact/relays of the protection relay.
6.1.5
Location of Current Transformers It is preferred that the CT’s are located on the busbar side of the feeder circuit breakers. However where this is not practicable, the current transformers for feeder protection may be located on the line side of the feeder circuit breaker. In this arrangement an inter-trip shall be provided to trip the feeder circuit breaker at the far end of the feeder whenever the local feeder circuit breaker is tripped. The far end circuit breaker is only required to trip if fault current is flowing through that circuit breaker. Refer to Section 5.9 Inter-Trip Arrangements for further details on inter-tripping. See Appendix J for typical Pilot Wire arrangements.
6.1.6
Metering Requirements Every feeder shall be provided with an ammeter and all bulk supply feeders shall be provided with kWh metering. Details of the ammeter, metering and their connection are specified in the appropriate switchgear standard. The requirements for 33kV indoor switchgear are detailed in EP 01 00 00 01 SP 33kV AC Indoor Switchgear – Non-Withdrawable.
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6.2 11kV feeders 6.2.1
Standard Protection Schemes The 11kV network supplies a large variety of installations with varying degrees of operational criticality. These installations range from underground stations, major signal boxes to minor maintenance locations supplied from pole mounted transformers. The criticality of the installation, accessibility of the 11kV feeder and the fault level determines the type of protection to be provided.
6.2.2
Primary Protection The following list details the requirement for the primary protection to be a pilot wire scheme. • 11kV feeders supplying underground railway stations. • 11kV feeders supplying major signal boxes • 11kV feeders installed in tunnels • 11kV feeders supplying installations deemed to be operationally critical • 11kV feeders where it is time critical to clear the fault due to high fault levels or bushfire hazards. All pilot wire schemes shall include pilot circuit supervision. This can be implemented either as a function of the pilot wire relay or using dedicated pilot circuit supervision equipment. Where the primary protection scheme is not required to be a pilot wire scheme, the feeder shall be protected with an over-current and earth fault scheme.
6.2.3
Backup protection The primary protection on the feeder shall be backed up by an over-current and earth fault scheme. Where the primary protection is a pilot wire scheme, the backup over-current and earth fault scheme can be located on the same circuit breaker panel, however the scheme must operate via a separate protection relay and ACCB trip coil. Where the primary protection is not a pilot wire scheme, the backup overcurrent and earth fault scheme shall operate via a circuit breaker and current transformers that are not part of the primary scheme.
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Where the primary protection is an overcurrent and earth fault scheme and is located on a 11kV switchboard supplied directly from a transformer, a neutral leakage relay shall be used as backup protection for earth faults. The transformer primary overcurrent protection may be used to backup feeder overcurrent protection. This is subject to the transformer overcurrent settings being suitable. 6.2.4
Circuit Breaker Fail Scheme The failure of a circuit breaker to open in response to a protection trip command shall be detected and all ACCB’s on the same busbar section as the failed ACCB shall be tripped via a multi-trip relay. The multi-trip relay used to implement this may be the bus-zone multi-trip relay. If the feeders are protected by a pilot wire scheme then the appropriate upstream circuit breaker(s) shall be tripped. A time delay (0.2s) shall be provided to avoid nuisance tripping. It is preferred that the protection relays provide this function.
6.2.5
Location of Current Transformers It is preferred that the CT’s are located on the busbar side of the feeder circuit breakers. However where this is not practicable, the current transformers for feeder protection can be located on the line side of the feeder circuit breaker. This is subject to RailCorp approval.
6.2.6
Metering Requirements Every feeder shall be provided with an ammeter and all feeders that are a dedicated supply to commercial premises (eg, train maintenance centres) shall be provided with kWh metering. Details of the ammeter, metering and their connection are specified in the appropriate switchgear standard.
6.3
High Voltage Busbars & Bus-Tie Cables
6.3.1
Primary Protection for Busbars All 33kV and 66kV indoor switchgear shall have bus zone protection as the primary protection for the busbar. The requirement for 11kV indoor switchgear to have bus zone protection depends whether the location is a:
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strategic location
•
location with high fault levels
•
location where there is more than one busbar section
EP 19 00 00 02 SP
The traditional high impedance bus-zone protection scheme using CT’s is an approved RailCorp scheme. A fault detection scheme that has been type tested and is an integral system within the switchgear may be offered for consideration by RailCorp and if approved will be the preferred scheme. Strategically important outdoor 33kV and 66kV busbars shall also have high impedance bus zone protection as the primary protection. The criteria for this decision will be provided in a later version of this document. Separate schemes shall be provided for each section of the busbar. All ACCB’s on the associated bus-section shall be tripped. Close inhibit shall also be implemented, refer to Section 5.7 The tripping of circuit breakers on an indoor switchboard shall be via a MTM relay. The tripping of circuit breakers on an outdoor busbar shall be via an MTA relay. 6.3.2
Primary Protection for Bus-tie Cables All bus-tie cables interconnecting 11kV, 33kV and 66kV indoor switchboards shall have high impedance bus zone protection as the primary protection. The scheme shall be arranged to trip the circuit breakers at both ends of the tie cable via a manually reset multi-trip relay. Close inhibit shall also be implemented, refer to Section 5.7
6.3.3
Backup Protection The backup protection for a busbar shall be upstream over-current and earth fault protection. The backup protection for a bus-tie shall be upstream over-current and earth fault protection except where the switchboard directly interfaces with a Supply Authority. Where the switchboard interfaces with a Supply Authority the bus-tie cables shall have a duplicate high impedance protection scheme as the backup protection. Refer to Appendix A for the type of relay to be used.
6.3.4
Location of Current Transformers The current transformers for protection of the busbar shall be located on the line side of all circuit breakers.
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The current transformers for protection of the bus-tie cables shall be located on the busbar side of the tie circuit breaker. Where the current transformers for the feeder, bus-tie, or transformer circuits are not located on the busbar side of the circuit breaker and the bus zone scheme is used to cover the blind spots between the circuit breakers and the CT’s, then the bus-zone scheme shall also initiate tripping of the circuit breakers at the far end of the feeder or tie cable, or on the other winding of the transformer.
6.4
Rectifier Transformer and Power Cubicle
6.4.1
Primary Protection The primary protection for the rectifier transformer and power cubicle shall be provided by an A∅ and C∅ instantaneous overcurrent and instantaneous earth fault relay. If the transformer is cable connected (terminals/bushings are not exposed), the circuit breaker shall be tripped via a MTM relay for earth faults. The overcurrent elements are required to operate when a fault on the +1500V DC busbar (when there is a 400V arc) is detected. A current transducer shall be provided in the B∅ protection circuit. The transducer output shall be connected to the panel ammeter and analogue input to SCADA. See EP 03 02 00 01 SP – Controls and Protection for Rectification Equipment, for further detailed information on these requirements.
6.4.2
Backup Protection The backup protection scheme for the rectifier transformer and power cubicle shall be provided by a separate protection scheme, which is located in the same substation. The protection relay shall be an A∅, B∅ and C∅ instantaneous overcurrent and instantaneous earth fault relay. If the transformer is cable connected, the circuit breaker shall be tripped via a MTM relay for earth faults.
6.4.3
Circuit Breaker Fail Scheme The failure of the circuit breaker to open in response to a protection trip command shall be detected and the associated bus-zone MTM relay shall be energised. A time delay of 0.2 seconds shall be provided to avoid nuisance tripping. It is preferred that the protection relays provide this function
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6.4.4
EP 19 00 00 02 SP
Protection Interface Requirements Refer to EP 03 02 00 01 SP – Controls and Protection for Rectification Equipment, for further detailed information on the protection interface requirements.
6.5
System Transformers
6.5.1
Standard Protection Schemes All 33kV and 66kV transformers 750MVA or greater in size shall have transformer differential as the primary protection and overcurrent and earth leakage as the backup protection. Oil filled transformers shall be fitted with a buchholz oil & gas relay.
6.5.2
Primary Protection The transformer differential scheme shall be arranged to trip both the primary and secondary circuit breakers. The tripping of the circuit breakers shall be via a multi-trip relay. If the transformer is cable connected (terminals/bushings not exposed) the multi-trip relay shall be a manually reset relay.
6.5.3
Backup Protection Overcurrent and earth fault shall be provided as the backup transformer protection. The tripping of the circuit breakers shall be via a multi-trip relay. If the transformer is cable connected (terminals/bushings not exposed) the multi-trip relay shall be a manually reset relay for earth faults and an automatically reset relay for overcurrent faults. Three phase over current protection shall be provided on the high or low voltage side of the transformer as backup protection to the outgoing feeder overcurrent protection.
6.5.4
Circuit Breaker Fail Scheme The failure of a circuit breaker to open in response to a backup protection trip command shall be detected and the associated bus-zone MTM relay energised. A time delay of 0.2 seconds shall be provided to avoid nuisance tripping. The three phase overcurrent protection relay on the same side of the transformer as the scheme being backed up shall provide this function.
6.5.5
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Neutral Leakage
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Neutral leakage shall be provided as backup protection to feeder earth fault. The scheme shall trip both the primary and secondary circuit breaker of the transformer via an MTA relay. 6.5.6
Buchholz Relay A buchholz relay shall be provided in the oil line between the conservator and the main tank. Operation of either the oil or gas element of the buchholz relay shall trip both the primary and secondary circuit breakers via a manually reset multi-trip relay. Each element of the buchholz relay shall have voltage free alarm contacts, which are connected to the SCADA system.
6.5.7
Location of Current Transformers It is preferred that the current transformers for the differential protection are located on the busbar side of both the primary and secondary circuit breakers. Where this is not practicable, it is acceptable that the current transformers for transformer protection be located on the transformer side of the transformer circuit breaker. The current transformer for the neutral leakage protection shall be located on the neutral to earth connection of the transformer.
6.6
11kV/415V Transformers
6.6.1
Transformers Supplied from Ring Main Units All 11kV distribution transformers (200kVA and above up to 800kVA), that are supplied via an ACCB from a RMU shall be protected by a Merlin Gerin VIP300LL protection relay. An MMLG01 test block shall be fitted adjacent to the relay. Transformers less then 200kVA shall be protected by fuses. The VIP300LL relay can not be used for transformers less then 200kVA as there may be insufficient magnetising current to meet the self powering requirements of the relay.
6.6.2
Transformers Supplied from SCADA Controlled ACCB’s
6.6.3
Standard Protection Schemes All 11kV transformers 750kVA or greater in size shall have transformer differential as the primary protection and overcurrent and earth leakage as the backup protection. Oil filled transformers shall be fitted with a buchholz oil & gas relay.
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For transformers < 750kVA primary protection shall be overcurrent and earth leakage. Transformer differential schemes may be used on smaller transformers where required to ensure that the transformer protection grades over the LV protection. 6.6.4
Primary Protection The transformer differential scheme shall be arranged to trip both the primary and secondary circuit breakers. The tripping of the circuit breakers shall be via a multi-trip relay. If the transformer is cable connected (terminals/bushings not exposed) the multi-trip relay shall be a MTM relay.
6.6.5
Backup Protection Overcurrent and earth fault shall be provided as the backup transformer protection. The backup protection scheme is not required to detect faults on the LV winding of a distribution transformer or the LV cables. The tripping of the circuit breakers shall be via a multi-trip relay. If the transformer is cable connected (terminals/bushings not exposed) the multi-trip relay shall be a MTM relay for earth faults and an MTA relay for overcurrent faults.
6.6.6
Circuit Breaker Fail Scheme The failure of a circuit breaker to open in response to a backup protection trip command shall be detected and the associated bus-zone MTM relay energised. A time delay of 0.2 seconds shall be provided to avoid nuisance tripping. It is preferred that the protection relays provide this function.
6.7
DOCUMENTATION REQUIREMENTS There are three distinct stages for the submission of documentation related to the protection design and implementation for RailCorp to review.
6.7.1
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The first stage is the concept design documentation.
2)
The second stage is the submission of the detailed design documentation.
3)
The third stage is the submission of all testing, commissioning and as-built documentation.
Concept Design Documentation
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The following documentation is to be submitted to RailCorp prior to the procurement of any equipment that is required to meet comply with this standard:
6.7.2
•
Approved operating diagrams
•
Fault levels
•
Protection concept design. This document shall include: •
Diagrams detailing the functionality of the protection schemes
•
Text document outlining in detail the protection schemes. This document shall include such details as: functional description of protection schemes, current transformer details, protection relay types, trip coil, SCADA alarms, analogue details, auxiliary battery details.
•
Calculations (eg. CT knee-point voltage, VT burdens, fault levels)
•
High voltage equipment specifications
Detail Design Documentation The following documentation is required to be submitted to RailCorp prior to the approval of equipment manufacture.
6.7.3
•
Schematic diagrams
•
Equipment arrangement / layout drawings
•
Equipment label schedule
Commissioning Documentation The following commissioning documentation is required to be submitted to RailCorp prior to the energisation of equipment.
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Equipment FAT test results
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Primary injection test results
•
Secondary injection test results
•
Protection relay/scheme functionality checklists
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Protection relay software setting files
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Protection grading studies
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Protection instructions
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Equipment operating and maintenance manuals
•
As-built documentation (drawings, schedules etc)
•
Related test documentation to ensure the safe operation of the equipment (eg. earthing test results)
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Appendix A
Protection Relays
Appendix A.1
Approved Protection Relays
EP 19 00 00 02 SP
The following tables detail the requirements for protection relays when new switchboards are installed in the RailCorp electrical Network. The tables detail the protection relays which are currently preferred for use in the RailCorp electrical network and when installing a new switchboard in an existing system whether the existing pilot wire relays are required to be replaced.
SCHEME
EQUIPMENT
RELAY TYPE
Supply point feeder
MHOB04, MiCOM P521/P540, SIEMENS 7SD610 (mandatory if fibre optic available)
Pilot Wire RailCorp feeder
MBCI02* or MiCOM P521/P541 (mandatory if fibre optic available)
OC, EF, DOC, DEF
Feeder
KCEG142, MiCOM P127
Rectifier - primary
MCAG33 or MiCOM P124
Rectifier - backup
KCEG142 or MiCOM P127
Current check
MCAG39 or MiCOM P122
System Transformer
MiCOM P127
11kV Distribution Transformer
VIP35
(refer Section 6.6) Busbar
MCAG34
Bus-zone
Bus-tie cable
MCAG34, P127 (when duplicate protection required)
Transformer differential
SystemTransformer
KBCH120,
(2 winding)
MiCOM P632
Neutral leakage
Transformer
KCEG142 or MiCOM P127
MTA
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SCHEME
EQUIPMENT
EP 19 00 00 02 SP
RELAY TYPE
MTM
MVAJ13 (hand reset with flag)
Intertrip
GCM05 (15kV isolation)
TCS
RMS 1TM10
Bus Supply
48V DC supply
RMS 1X10CAA
125V DC supply
RMS 1X10EAA
TABLE A1: Protection Relays •
Appendix A.2
The MBCI02 pilot wire relay is a specific model for use on the RailCorp system. The relay has been modified to produce a lower voltage suitable for the insulation level of communication pilots and is Austel approved.
Location of Protection Relays
The physical location of protection relays will depend on the type of switchgear installed. In general the protection relays and associated test blocks for specific equipment shall be located together on the same panel. This is usually on the low voltage compartment of the switchgear panels themselves (indoor switchgear) or on dedicated protection panels (for outdoor ACCB’s or indoor switchgear that does not have the physical space for installing the relays). The particular requirements for specific relays and equipment are detailed below:
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Transformer protection - MTA and MTM relays located on the primary protection panel.
•
33/11kV transformer – neutral leakage relay shall be located on the 11kV switchgear panel.
•
Bus-zone protection relay and associated MTM relay located on the appropriate end panel.
•
Bus cable tie protection relay and associated MTM relay located on either of the associated bus tie ACCB panels.
•
Pilot wire isolation transformers shall be located as close as possible to the termination enclosure of the pilot cable.
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Appendix B
EP 19 00 00 02 SP
ACCB Trip Coils - Standard Equipment Connection
The following table details the ACCB trip coils and associated relays that are connected to each trip coil. This table is based on typical protection schemes used in RailCorp. Protection designs for specific locations must be verified by RailCorp. Refer to 6.1.1 for additional requirements relating to breaker fail schemes and Supply Points.
EQUIPMENT
PROTECTION SCHEME
TRIP COIL NUMBER
Feeder Protection
Pilot wire
1
Overcurrent & Earth Fault
2
Inter-trip
1
Busbar protection – trips via MTM
2
1
Cable Bus-tie protection – trips via MTM
1
4
Differential – trips via MTM or MTA
1
Overcurrent – trips via MTA
1,2
Neutral Leakage – trips via MTA
2
Differential – trips via MTM or MTA
1
Overcurrent – trips via MTA
1,2
2, 5
Rectifier Instantaneous Overcurrent Transformers Earth Fault (primary prot’n)
1
3
Rectifier Transformers
Instantaneous Overcurrent
2
Earth Fault
2 & 1 via MTM
MTM
1
Bus-zone & Bus-Tie
System Transformers
11kV/415V Transformers
(backup prot’n) Rectifier Transformer
NOTES
2
1 via MTM 3
TABLE B1: Trip Coils Notes:
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1)
The operation of the bus-zone protection energises an MTM relay, which trips all ACCB’s on the section of the busbar. The trip coil number applies to all ACCB’s that are tripped.
2)
If the differential protection operates via an MTM then the overcurrent protection shall trip via trip coil 2.
3)
Refer to 6.4 for requirements of when earth faults are required to energise MTM.
4)
When there is duplicate protection on the bus-tie cable the duplicate scheme shall trip the ACCB’s via trip coil 2 (via an MTM).
5)
If there is no differential protection, then the overcurrent protection shall trip via trip coil 1.
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Appendix C
EP 19 00 00 02 SP
Two Battery Systems (125V DC) - Standard Protection Equipment Connection
The following table details the battery system that the ACCB trip coils and protection relays should be connected to. This table is based on typical protection schemes used by RailCorp. When there are two battery systems the equipment should be connected across the two battery systems to obtain balanced loads as close as possible. Protection designs for specific locations must be verified by RailCorp. Refer to 5.5.2 for details of the requirement for two battery systems.
PRIMARY PROTECTION PRIMARY & BACKUP ONLY PROTECTION LOCATED IN SAME SUBSTATION ONE TRIP COIL
• •
TWO BATTERY SYSTEMS TWO TRIP COILS
• • •
Protection relay supply from one battery Trip coil supply from same battery as relay supply
•
Protection relay supply from one battery Trip coil 1 supply from battery 1 Trip coil 2 supply from battery 2
•
• •
• • •
Primary protection relay supply from battery 1 Backup protection relay supply from battery 2 Trip coil supply from battery 1 Primary protection relay supply from battery 1 Backup protection relay supply from battery 2 Trip coil 1 supply from battery 1 Trip coil 2 supply from battery 2
TABLE C1: Two Battery Systems – Connection of Equipment Notes: 1) 2)
JUNE 2007
When there is only one battery system, the two trip coils must be supplied from separate submains originating from the 125V DC distribution board. Refer to Appendix N for typical arrangement of auxiliary supplies to HV switchboards. This diagram illustrates the principle; however detailed design is required to ensure security of the protection scheme.
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Appendix D
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Interfacing With Existing Pilot Wire Schemes
The following table details whether the existing pilot wire scheme needs to be upgraded when a new switchboard is to be installed, and is interfacing with an existing pilot wire protection scheme.
SCHEME
Pilot wire
EXISTING EQUIPMENT
SCHEME TO BE REPLACED
NOTES
HO2
YES
HO4
NO
2
HMB4
NO
1,2
MHOB04
NO
1
MBCI02
NO
1
MiCOM P521/P541
NO
TABLE D1: Interfacing With Existing Pilot Wire Schemes Notes: 1)
2)
JUNE 2007
If there are fibre optic pilots available between substations or fibre is to be installed, then pilot wire relays that use fibre optic for their communication (MiCOM P521/P541) shall be used. If system spares are to be used to create/interface with an H04 or HMB4 scheme then the RailCorp Protection Engineer shall be consulted to ensure there are adequate spares available. If the number of spares available is at the minimum required number, then the pilot wire scheme shall be replaced.
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Appendix E
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Current Transformers (33kV & 66kV)
The following tables detail the ratio and designation of current transformers, which are to be used in the RailCorp electrical network for typical schemes on the 66kV & 33kV high voltage system. The current transformer designation details are calculated based on the following parameters: •
Maximum CT secondary lead (loop) length of 20m with 2.5mm2 size cable for indoor equipment and a lead (loop) length of 150m with 16mm2 size cable for outdoor equipment.
•
CT core knee point flux density of 1.45T
•
System X/R = 5
•
MICOM P521 relay, refer to general equations for X/R 20m.
•
System transformers with a size or voltage not specified below.
•
Transformers with a different configuration.
•
Feeders with a higher capacity than 500A.
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Appendix E.1
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Rectifier Instantaneous Overcurrent & Earth Fault
EQUIPMENT
Rectifier Tx – 33kV
Rectifier Tx – 66kV
VOLTAGE /SIZE
CT RATIO
5.3, 4.28 & 2.5MVA
300/200/5
5.3, 4.28, 2.5MVA
150/100/5
RELAY TYPE
CT DESIGNATION
MCAG33
10 P100F20 (specified on 200 tap)
MiCOM P127
10 P50F20 (specified on 200 tap)
MCAG33
10 P100F20 (specified on 100 tap)
MiCOM P127
10 P50F20 (specified on 100 tap)
TABLE E1: Rectifier Protection Relays & CT’s
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Appendix E.2
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Overcurrent and Earth Fault
CT’s for use on overcurrent and earth leakage on feeders have been sized on a fault level of 31.5kA at 33kV and 15.75kA at 66kV.
EQUIPMENT
VOLTAGE /SIZE
66kV Feeder
33kV Feeder
33/11KV Tx (5MVA )
SCHEME
CT RATIO
OC & EF
250/5
OC & EF
33KV
OC & EF
RELAY TYPE
CT DESIGNATION
KCEG142
10P150
MiCOM P127
10P150
KCEG142
10P300 (specified on 300 tap)
MiCOM P127
10P300 (specified on 300 tap)
MiCOM P127
10P50F20
500/400 /300/5
150/5
TABLE E2: Overcurrent and Earth Fault Protection Relays & CT’s
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Appendix E.3
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Pilot Wire Schemes
CT’s for use on pilot wire schemes have been sized on a fault level of 31.5kA at 33kV and 15.75kA at 66kV
EQUIPMENT
CT RATIO
RELAY TYPE
CT DESIGNATION
MBCI02 or MiCOM P521/P541
0.3PL115R0.3
250/5
MBCI02 or MiCOM P521/P541
0.05PL50R0.8
250/1
500/400/300/5
MBCI02 or MiCOM P521/P541
0.3 PL200R0.3 (specified on 300 tap)
500/400/300/1
MBCI02 or MiCOM P521/P541
0.05 PL80R0.8 (specified on 300 tap)
66kV Feeder
33kV Feeder
TABLE E3: Pilot Wire Protection Relays & CT’s
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Appendix E.4
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Bus-Zone Schemes & Transformer Differential
The overall design of a bus-zone scheme is critical to ensure stability for through faults. The requirement for stabilising resistors to ensure stability and for metrosils to limit CT output voltage shall be determined for each individual scheme. Please refer to the AREVA MCAG34 application brochure for methods of calculation and requirements. CT’s for use on bus-zone schemes have been sized on a fault level of 31.5kA.
EQUIPMENT
RELAY TYPE
CT RATIO
CT DESIGNATION
33kV Buszone
MCAG34
1250/5
0.1 PL200R0.4
33/11kV Tx 5MVA, Dyn1
KBCH120 (two winding),
33kV -
(differential)
MiCOM P632
150/5
2.5P50F20
TABLE E4: Bus-Zone & Transformer Differential Protection Relays & CT’s Notes: 1)
JUNE 2007
The P632 relay should be ordered with an extra I/O module. This is required to allow for the transformer and tapchanger alarms.
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Appendix F
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Current Transformers for 11kV Switchgear
The following current transformer details are typical values only. The CT specification shall be determined for specific individual applications and is subject to RailCorp approval.
EQUIPMENT
SCHEME
CT RATIO
RELAY TYPE
CT DESIGNATION
11kV Feeder
Pilot Wire
11kV Feeder
300/1
MiCOM P521
0.05PL50R1.0
OC & EF
300/150/1
MiCOM P127
10P50F20
Differential
450/0.577
MiCOM P632
0.02PL100R3.0
OC & EF
450/1
MiCOM P127
10P50F20
Neutral leakage
150/1
MiCOM P127
10P50F20
11KV/415V Tx (1MVA )
Differential
100/1
MiCOM P632
0.15L50R0.3
1
Busbar
Buszone
600/1
MCAG34
0.03PL120R2.0
2
Bus-tie Cables
Buszone
600/1
MCAG34
0.03PL120R2.0
2
33/11kV Tx (6.25 MVA )
Notes
1
Notes:
JUNE 2007
1)
The rated primary current value will depend on the size of the transformer.
2)
The rated primary current value will depend on the rating of the busbar.
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Appendix G
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Protection Relay Identification
Device numbers and functions shall generally be in accordance with IEEE C.37.2. The detailed implementation shall be as set out below.
Relay Identifier Description 50A
Instantaneous Overcurrent Relay (A phase)
50C
Instantaneous Overcurrent Relay (C phase)
50/L
Instantaneous Overcurrent Relay (A,C & E; feeder)
50/T
Instantaneous Overcurrent Relay (A,C & E; transformer)
50/T1
Instantaneous Overcurrent Relay – Backup (A,C & E; transformer)
51A
Inverse Time Overcurrent Relay (A phase)
51C
Inverse Time Overcurrent Relay (C phase)
63
Buchholz Relay
64
Instantaneous Earth Fault Relay
67
Directional Overcurrent Relay
67/L
Directional Overcurrent Relay (feeder)
87/B
Differential Protective Relay (busbar – high impedance)
87/BT
Differential Protective Relay (bus-tie cable – high impedance)
87/L
Differential Protective Relay (feeder - pilot wire scheme)
87/T
Differential Protective Relay (transformer)
MTA
Multi Trip Automatic Reset Relay
MTM
Multi Trip Manual Reset Relay
SRR
Send Receive Relay
TBK1, 2
Test Block
TCS
Trip Circuit Supervisory Relay TABLE F1: Protection Relay Identification
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Appendix H
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Standard Test Block Wiring & Input/Output Relay Configuration
The following test block, protection relay input and output configurations are based on the majority of existing configurations in the RailCorp network. The configurations do not determine the requirement for a particular protection function, but detail the test block connections and output or input relay if that function is to be implemented. It is not general practice to connect alarms via the test block or connect spare output relays to the test block. The test block shall be located adjacent to the protection relay it is associated with. It is important that new installations comply with these diagrams as they affect the programming of electronic relays, the testing procedures for periodic maintenance and the production of standard designs. Any deviations from the standard configuration must be approved by the Protection Engineer.
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PILOT WIRE PROTECTION MBCI+MCRI Check RELAYS
Relay
Incoming Supplies MMLG01
MBCI RELAY 1-1 contact MBCI RELAY 1-1 contact MCRI check contact MCRI check contact Pilot 1 MBCI (17) Pilot 2 MBCI (18) MBCI&MCRI Aux MBCI&MCRI Aux
Ia (MBCI&MCRI) Ib (MBCI&MCRI) Ic (MBCI&MCRI) Io (MBCI&MCRI)
______2____x____1_____ ______4____x____3_____ ______6____x____5_____ ______8____x____7_____ ______10___x____9_____ ______12___x___11_____ ______14___║___13_____ ______16___x___15_____ ______18___x___17_____ ______20___x___19_____ ______22___x___21_____ ______24___x___23_____ ______26___x___25_____ ______28___x___27_____
Trip +ve Pilot Wire Trip MBCI inhibit(11) Pilot 1 Pilot 2 + 125V dc Aux Supply - 125V dc Aux Supply
Ia Ib Ic Io
MBCI RELAY OUTPUT RELAYS RELAY 1-1 RELAY 1-2 RELAY 2-1 RELAY 2-2
JUNE 2007
PILOT WIRE TRIP PILOT WIRE TRIP ALARM INTERTRIP SEND SPARE
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MBOH04 RELAY
Relay
Incoming Supplies MMLG01
MB0H04 contact (1) MB0H04 contact (3)
Pilot 1 MB0H04 Pilot 2 MBOH04
Ia (MBCI&MCRI) Ib (MBCI&MCRI) Ic (MBCI&MCRI) Io (MBCI&MCRI)
JUNE 2007
Version 3.4
______2____x____1_____ ______4____x____3_____ ______6____x____5_____ ______8____x____7_____ ______10___x____9_____ ______12___x___11_____ ______14___║___13_____ ______16___x___15_____ ______18___x___17_____ ______20___x___19_____ ______22___x___21_____ ______24___x___23_____ ______26___x___25_____ ______28___x___27_____
© RailCorp
Trip +ve Pilot Wire Trip Spare Spare Pilot 1 Pilot 2 Spare Spare
Ia Ib Ic Io
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P521 RELAY
Relay
Incoming Supplies MMLG01
RELAY 1 contact RELAY 1 contact
______2____x____1_____ ______4____x____3_____ ______6____x____5_____ ______8____x____7_____ ______10___x____9_____ ______12___x___11_____ ______14___║___13_____ ______16___x___15_____ ______18___x___17_____ ______20___x___19_____ ______22___x___21_____ ______24___x___23_____ ______26___x___25_____ ______28___x___27_____
TERMINAL 33 TERMINAL 34 RELAY 8 contact RELAY 8 contact Ia Ib Ic Io
Trip +ve Pilot Wire Trip Spare Spare Spare Spare + 125V dc Aux Supply - 125V dc Aux Supply Trip +ve Breaker Fail Trip Ia Ib Ic Io
OUTPUT RELAYS: RELAY 1 PILOT WIRE TRIP RELAY 2 TCS ALARM RELAY 3 PILOT WIRE TRIP ALARM RELAY 4 COMMS FAIL ALARM RELAY 5 SPARE RELAY 6 BREAKER FAIL ALARM RELAY 7 SPARE RELAY 8 BREAKER FAIL TRIP INPUT RELAYS: L1 L2 L3 L4 L5
JUNE 2007
INTERTRIP INITIATE TCS INPUT SPARE SPARE SPARE
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SIEMENS 7SD610 RELAY
Relay
Incoming Supplies MMLG01
RELAY BO4 contact RELAY BO4 contact
RELAY BO5 contact RELAY BO5 contact TERMINAL F1 TERMINAL F2 RELAY BO3 contact RELAY BO3 contact Ia Ib Ic Io
______2____x____1_____ ______4____x____3_____ ______6____x____5_____ ______8____x____7_____ ______10___x____9_____ ______12___x___11_____ ______14___║___13_____ ______16___x___15_____ ______18___x___17_____ ______20___x___19_____ ______22___x___21_____ ______24___x___23_____ ______26___x___25_____ ______28___x___27_____
Trip +ve Pilot Wire Trip Spare Spare Trip +ve Intertrip Trip + 125V dc Aux Supply - 125V dc Aux Supply Trip +ve Breaker Fail Trip Ia Ib Ic Io
OUTPUT RELAYS: BO1 EA ACCB STATUS BO2 COMMS FAIL ALARM BO3 BREAKER FAIL TRIP BO4 PILOT WIRE TRIP BO5 INTERTRIP RECEIVE Note: Output relays BO1, BO2 & BO3 are not voltage free contacts. The +125V DC for the breaker fail trip is also connected to B01 & B02 contacts by internal relay wiring.
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RECTIFIER OC & EF PROTECTION P127 RELAY
Relay
Incoming Supplies MMLG01
RELAY 1 contact RELAY 1 contact RELAY 3 contact RELAY 3 contact
______2____x____1_____ ______4____x____3_____ ______6____x____5_____ ______8____x____7_____ ______10___x____9_____ ______12___x___11_____ ______14___║___13_____ ______16___x___15_____ ______18___x___17_____ ______20___x___19_____ ______22___x___21_____ ______24___x___23_____ ______26___x___25_____ ______28___x___27_____
TERMINAL 33 TERMINAL 34 RELAY 8 contact RELAY 8 contact Ia Ib Ic Io
Trip +ve Overcurrent Trip Trip +ve Earth Fault Trip Spare Spare + 125V dc Aux Supply - 125V dc Aux Supply Trip +ve Breaker Fail Trip Ia Ib Ic Io
OUTPUT RELAYS: RELAY 1 OVERCURRENT & EARTH FAULT TRIP RELAY 2 TCS ALARM RELAY 3 EARTH FAULT TRIP RELAY 4 OVERCURRENT ALARM RELAY 5 EARTH FAULT ALARM RELAY 6 BREAKER FAIL ALARM RELAY 7 SPARE RELAY 8 BREAKER FAIL TRIP INPUT RELAYS: INPUT L1 INPUT L2 INPUT L3 INPUT L4 INPUT L5 INPUT L6 INPUT L7
JUNE 2007
SPARE SPARE SPARE TCS TIMER INITIATE SPARE SPARE
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RECTIFIER OC & EF PROTECTION MCAG33 RELAY Relay
Incoming Supplies MMLG01
MCAG trip contact MCAG trip contact Spare trip contact Spare trip contact Spare Spare Spare Spare Spare Spare Ia Ib Ic Io
______2____x____1_____ ______4____x____3_____ ______6____x____5_____ ______8____x____7_____ ______10___x____9_____ ______12___x___11_____ ______14___║___13_____ ______16___x___15_____ ______18___x___17_____ ______20___x___19_____ ______22___x___21_____ ______24___x___23_____ ______26___x___25_____ ______28___x___27_____
MVAJ13 Trip +ve MVAJ13 Trip Spare trip contact Spare trip contact Spare Spare Spare Spare Spare Spare Ia Ib Ic Io
RELAY CONTACTS: A∅ contacts:
terminals 1 & 3 : trip 2 & 4 SCADA alarm
E/F contacts:
terminals 5 & 7 : trip 6 & 8 SCADA alarm
C∅ contacts:
terminals 9 & 11 : trip 10 & 12 SCADA alarm
Notes: 1. A & C phase trip contacts are connected in parallel at the relay terminals.
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33/11kV TRANSFORMER OC & EF PROTECTION
P127 RELAY Relay
Incoming Supplies MMLG01
RELAY 7 contact RELAY 7 contact RELAY 3 contact RELAY 3 contact
______2____x____1_____ ______4____x____3_____ ______6____x____5_____ ______8____x____7_____ ______10___x____9_____ ______12___x___11_____ ______14___║___13_____ ______16___x___15_____ ______18___x___17_____ ______20___x___19_____ ______22___x___21_____ ______24___x___23_____ ______26___x___25_____ ______28___x___27_____
TERMINAL 33 TERMINAL 34 RELAY 8 contact RELAY 8 contact Ia Ib Ic Io
Trip +ve Overcurrent Trip Trip +ve Earth Fault Trip Spare Spare + 125V dc Aux Supply - 125V dc Aux Supply Trip +ve Breaker Fail Trip Ia Ib Ic Io
OUTPUT RELAYS: RELAY 1 NOT AVAILABLE * RELAY 2 TCS ALARM RELAY 3 EARTH FAULT TRIP RELAY 4 OVERCURRENT ALARM RELAY 5 EARTH FAULT ALARM RELAY 6 BREAKER FAIL ALARM RELAY 7 OVERCURRENT TRIP RELAY 8 BREAKER FAIL TRIP
INPUT RELAYS: INPUT L1 INPUT L2 INPUT L3 INPUT L4 INPUT L5 INPUT L6 INPUT L7
SPARE SPARE SPARE TCS SPARE SPARE SPARE
* THE BREAKER FAIL FUNCTION OF THE RELAY IS INITIATED INTERNALLY BY RELAY 1. HENCE RELAY 1 IS PROGRAMMED TO BE ENERGISED FOR EITHER AN OVERCURRENT OR EARTH FAULT TRIP. HOWEVER, IT IS NOT CONNECTED EXTERNALLY AS AN OVERCURRENT TRIP IS REQUIRED TO ENERGISE AN MTA RELAY AND THE EARTH FAULT TRIP IS REQUIRED TO ENERGISE AN MTM RELAY.
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11kV DISTRIBUTION TRANSFORMER OC & EF PROTECTION VIP35 RELAY
Relay
Incoming Supplies MMLG01
TERMINAL 2 TERMINAL 3
______2____x____1_____ ______4____x____3_____ ______6____x____5_____ ______8____x____7_____ ______10___x____9_____ ______12___x___11_____ ______14___║___13_____ ______16___x___15_____ ______18___x___17_____ ______20___x___19_____ ______22___x___21_____ ______24___x___23_____ ______26___x___25_____ ______28___x___27_____
TERMINAL 12 TERMINAL 13
TERMINAL 9 TERMINAL 10 TERMINAL 7 TERMINAL 8 TERMINAL 5 TERMINAL 6
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11kV DISTRIBUTION TRANSFORMER OC & EF PROTECTION VIP300LL RELAY
Relay (x1 range 4-50A)
Incoming Supplies MMLG01
TERMINAL 15 TERMINAL 16
______2____x____1_____ ______4____x____3_____ ______6____x____5_____ ______8____x____7_____ ______10___x____9_____ ______12___x___11_____ ______14___║___13_____ ______16___x___15_____ ______18___x___17_____ ______20___x___19_____ ______22___x___21_____ ______24___x___23_____ ______26___x___25_____ ______28___x___27_____
TERMINAL 12 TERMINAL 8 TERMINAL 11 TERMINAL 6 TERMINAL 10 TERMINAL 4
Trip -ve Trip +ve Spare Spare Spare Spare Spare Spare Ia Ia Ib Ib Ic Ic
VIP300LL RELAY
Relay (x4 range 50-200A)
Incoming Supplies MMLG01
TERMINAL 15 TERMINAL 16
______2____x____1_____ ______4____x____3_____ ______6____x____5_____ ______8____x____7_____ ______10___x____9_____ ______12___x___11_____ ______14___║___13_____ ______16___x___15_____ ______18___x___17_____ ______20___x___19_____ ______22___x___21_____ ______24___x___23_____ ______26___x___25_____ ______28___x___27_____
TERMINAL 12 TERMINAL 7 TERMINAL 11 TERMINAL 5 TERMINAL 10 TERMINAL 3
JUNE 2007
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Trip -ve Trip +ve Spare Spare Spare Spare Spare Spare Ia Ia Ib Ib Ic Ic
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FEEDER DOC & DEF PROTECTION P127 RELAY
Relay
Incoming Supplies MMLG01
RELAY 1 contact RELAY 1 contact Va Vb Vc Vn TERMINAL 33 TERMINAL 34 RELAY 8 contact RELAY 8 contact Ia Ib Ic Io
______2____x____1_____ ______4____x____3_____ ______6____x____5_____ ______8____x____7_____ ______10___x____9_____ ______12___x___11_____ ______14___║___13_____ ______16___x___15_____ ______18___x___17_____ ______20___x___19_____ ______22___x___21_____ ______24___x___23_____ ______26___x___25_____ ______28___x___27_____
Trip +ve Trip Va Vb Vc Vn + 125V dc Aux Supply - 125V dc Aux Supply Trip +ve Breaker Fail Trip Ia Ib Ic Io
OUTPUT RELAYS: RELAY 1 OVERCURRENT & EARTH FAULT TRIP RELAY 2 TCS ALARM RELAY 3 SPARE RELAY 4 OVERCURRENT ALARM RELAY 5 EARTH FAULT ALARM RELAY 6 BREAKER FAIL ALARM RELAY 7 INTERTRIP SEND (IF REQUIRED) RELAY 8 BREAKER FAIL TRIP
INPUT RELAYS: INPUT L1 INPUT L2 INPUT L3 INPUT L4 INPUT L5 INPUT L6 INPUT L7
JUNE 2007
SPARE SPARE SPARE TCS SPARE SPARE SPARE
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FEEDER DOC & DEF PROTECTION KCEG142 RELAY
Relay
Incoming Supplies MMLG01
KCEG142 trip contact KCEG142 trip contact Va Vb Vc Vn KCEG142 Aux KCEG142 Aux KCEG142 ACCB fail trip contact KCEG142 ACCB fail trip contact Ia Ib Ic Io
______2____x____1_____ ______4____x____3_____ ______6____x____5_____ ______8____x____7_____ ______10___x____9_____ ______12___x___11_____ ______14___║___13_____ ______16___x___15_____ ______18___x___17_____ ______20___x___19_____ ______22___x___21_____ ______24___x___23_____ ______26___x___25_____ ______28___x___27_____
52 Trip +ve 52 Trip Va Vb Vc Vn + 125V dc Aux - 125V dc Aux ACCB/fail trip +ve ACCB/fail multitrip Ia Ib Ic Io
OUTPUT RELAYS: RELAY 0 SPARE RELAY 1 BREAKER FAIL ALARM RELAY 2 SPARE RELAY 3 OVERCURRENT & EARTH FAULT TRIP RELAY 4 OVERCURRENT ALARM RELAY 5 EARTH FAULT ALARM RELAY 6 SPARE RELAY 7 BREAKER FAIL TRIP
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TRANSFORMER DIFFERENTIAL PROTECTION P632/MBCH RELAY
Relay
Incoming Supplies MMLG01
P632/MBCH trip contact P632/MBCH trip contact Spare Ia’’ (delta connected C.T’s) Ib’’ (delta connected C.T’s) Ic’’ (delta connected C.T’s) P632/MBCH Aux P632/MBCH Aux Spare Spare Ia Ib Ic Io
______2____x____1_____ ______4____x____3_____ ______6____x____5_____ ______8____x____7_____ ______10___x____9_____ ______12___x___11_____ ______14___║___13_____ ______16___x___15_____ ______18___x___17_____ ______20___x___19_____ ______22___x___21_____ ______24___x___23_____ ______26___x___25_____ ______28___x___27_____
OUTPUT RELAYS (P632): K901 TX DIFFERENTIAL TRIP
K701
K902 K903
RELAY HEALTHY BREAKER FAIL TRIP
K702 K703
K904 K905 K906 K907 K908
TX DIFFERENTIAL TRIP ALARM TX BUCHHOLZ GAS ALARM TX BUCHHOLZ OIL ALARM TAP CHANGER ALARM TCS ALARM
K704 K705 K706 K707 K708
MVAJ Trip +ve MVAJ Trip Spare Ia Ib Ic + 125V dc Aux - 125V dc Aux Spare Spare Ia Ib Ic Io
TAP CHANGER PRESSURE SWITCH ALARM BREAKER FAIL ALARM TAP CHANGER OIL SURGE ALARM SPARE SPARE SPARE SPARE SPARE
INPUT RELAYS (P632): U901 TAP CHANGER OIL SURGE OPERATION U902 TX BUCHHOLZ OIL SURGE OPERATION U903 TX BUCHHOLZ GAS OPERATION U904 TAP CHANGER ALARM U701 U702 U703 U704 U705 U706
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TAPCHANGER PRESSURE SWITCH TCS SPARE SPARE SPARE SPARE
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DIRECTIONAL OC/E FEEDER PROTECTION: RELAY: MCGG52 + METI
Relay
Incoming Supplies MMLG01
MCGG trip contact MCGG trip contact Va Vb Vc METI Aux MCGG &METI Aux MCGG Aux Vo1 (open delta voltage) Vo2 (open delta voltage) Ia Ib Ic Io
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______2____x____1_____ ______4____x____3_____ ______6____x____5_____ ______8____x____7_____ ______10___x____9_____ ______12___x___11_____ ______14___║___13_____ ______16___x___15_____ ______18___x___17_____ ______20___x___19_____ ______22___x___21_____ ______24___x___23_____ ______26___x___25_____ ______28___x___27_____
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FEEDER PROTECTION, OVERCURRENT & EARTH FAULT RELAY: MCGG52/82
Relay
Incoming Supplies MMLG01
MCGG trip contact MCGG trip contact Spare Spare Spare Spare MCGG Aux MCGG Aux Spare Spare Ia Ib Ic Io
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BUS – TIE / BUS ZONE PROTECTION MCAG34 RELAY
Relay
Incoming Supplies MMLG01
MCAG trip contact MCAG trip contact Spare trip contact Spare trip contact Spare Spare Spare Spare Spare Spare Ia Ib Ic Io
______2____x____1_____ ______4____x____3_____ ______6____x____5_____ ______8____x____7_____ ______10___x____9_____ ______12___x___11_____ ______14___║___13_____ ______16___x___15_____ ______18___x___17_____ ______20___x___19_____ ______22___x___21_____ ______24___x___23_____ ______26___x___25_____ ______28___x___27_____
Trip +ve Trip Spare trip contact Spare trip contact Spare Spare Spare Spare Spare Spare Ia Ib Ic Io
RELAY CONTACTS: A∅ contacts:
terminals 1 & 3 : trip 2 & 4 SCADA alarm
B∅ contacts:
terminals 5 & 7 : trip 6 & 8 SCADA alarm
C∅ contacts:
terminals 9 & 11 : trip 10 & 12 SCADA alarm
Notes: 1. A, B &, C phase trip contacts are connected in parallel at the relay terminals.
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RECTIFIER LOCAL BACKUP PROTECTION MVTT14 + MCTI39 RELAYS
Relay
Incoming Supplies/Contacts MMLG01
MCTI trip contact ______2____x____1_____ MCTI trip contact ______4____x____3_____ MCTI current check ______6____x____5_____ MCTI current check ______8____x____7_____ lLocal bu +ve ______10___x____9_____ MVTT start ______12___x___11_____ Local bu +ve ______14___║___13_____ Local bu -ve ______16___x___15_____ MVTT Breaker fail trip contact ______18___x___17_____ MVTT Breaker fail trip contact ______20___x___19_____ MCTI Ia ______22___x___21_____ MCTI Ib ______24___x___23_____ MCTI Ic ______26___x___25_____ MCTI Io ______28___x___27_____
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Appendix I
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Voltage and Current Transducers
Transducers that are to be used to provide the SCADA system with current and voltage information relating to the high voltage network shall have the following general characteristics: •
Output of 0…20mA
•
Mean sensing
•
Self powered
The following transducer is approved for connection in the protection current transformer circuit. •
Areva Istat 300; Type 3CAEA513AA (for CT’s with 1A secondaries)
•
Areva Istat 300; Type 3CAEA55GKA (for CT’s with 5A secondaries)
The following transducer is approved for connection in the voltage transformer circuit. •
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Areva Istat 300; Type 3VAEA5450A, (nominal input range of 0-125V ac to measure a 110V ac voltage transformer output, usually measuring the voltage between A∅ & C∅).
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Appendix J
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Pilot Wire Schemes
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Appendix K
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Auto Re-close on High Voltage Feeders
The RailCorp re-closure policy is as follows: In general, one auto re-close in 5 seconds by SCADA (ie the master station initiates the auto re-close if all the requirements are met). This policy applies to the following: •
2kV, 11kV, 33kV 66kV aerial lines
•
11kV, 33kV 66kV cables, no auto re-close
•
2kV signalling cables do have auto re-close because of the criticality of maintaining the supply and often the fault blows clear.
•
A feeder that is partially cable and partially aerial line is treated as aerial line.
The auto re-close is taken off 33kV and 66kV feeders that traverse areas considered to be a bush fire risk when fire bans are imposed. This is a master station function initiated by the ESO's. Auto re-close is also automatically inhibited for 10 minutes after a close control.
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Appendix L
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Protection SCADA Alarms
PROTECTION SCADA ALARMS ORIGIN OF ALARM SCADA ALARM NAME ACCB
COMMENTS
SpringCharged LowGas
The number of alarm stages will depend on the ACCB being installed.
LowGasLockOut MotorSupply MotorTrouble
PROTECTION RELAY
DirectionProtectionA DirectionProtectionB DirectionProtectionC DirectionRelayFail DirectionalDCSupply PilotWireTripA PilotWireTripB PilotWireTripC BrokenConductorA BrokenConductorB BrokenConductorC PilotWireComms PilotWireRelayFail OverCurrentA OverCurrentB
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PROTECTION SCADA ALARMS ORIGIN OF ALARM SCADA ALARM NAME
COMMENTS
OverCurrentC EarthLeakage InstOverCurrentA InstOverCurrentB InstOverCurrentC Inst_OC/ELtrip OverCurrentRelayFail BreakerFail NeutralLeakageProtection IntertripReceive IntertripSend BusZone1 BusZone2 BusZone3 BusZoneRelayFail DifferentialProtectionA DifferentialProtectionB DifferentialProtectionC DifferentialRelayFail TripCircuitSupervision TRANSFORMER
BuchholzGas BuchholzOil TCBuchholzGas
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These alarms originate from the
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PROTECTION SCADA ALARMS ORIGIN OF ALARM SCADA ALARM NAME
COMMENTS transformer tap changer.
TCBuchholzOil TCFail TCLowLimit TCHighLimit TCControlSupply TCInProgress TCIncomplete TCRefSupplyAlarm
VOLTAGE TRANSFORMER
TemperatureAlarm
This alarm originates from the temperature indicators on the transformer. There could possibly be several stages.
PhaseFailure
This alarm originates from a dedicated phase failure relay connected to the output of the VT.
DirectionalAlarm
This alarm originates from a LV circuit breaker that supplies the voltage to the specific directional protection relay.
DCCB Frame Leakage
DCFrameLeakage
BATTERY CHARGER
BattChargerAC These alarms originate from the battery charger and the exact alarms available will depend on the battery charger.
BattUnderVolts BattOverVolts BattConnected
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Not all the alarms in the above list will be applicable. When determining the proposed alarms the following factors must be considered: •
Type of relay
•
Capacity of RTU
•
Function of relay
•
Value adding of the alarm information to the EOC operator and RailCorp Protection Engineer.
In many existing locations some of the protection alarms (eg. TCS) are connected in parallel for each piece of equipment to give one general alarm. This was due to the limitations on the quantity of alarms that could be connected to the RTU at the time of installation.
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Appendix M
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Implementation Of SCADA Alarms & Control
The SCADA alarms and control to and from equipment can be implemented by hard wiring or using a high level interface such as a serial link. Electronic protection relays can be used to convey the information by using discrete output relays or via serial links. However certain information is critical for system operation and must be independent on the protection relay or communication link to the RTU. The following list details the SCADA alarms and control that are required to be hard wired to the RTU.
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•
ACCB control
•
ACCB indication (both open and closed)
•
ACCB DISCONNECTOR/ISOLATOR indication (all positions)*
•
EARTH SWITCH indication (both open and closed)*
•
Tapchanger control
•
Battery Charger alarm
•
Protection relay watchdog alarms
•
Trip Circuit Supervision (TCS), where provided by a dedicated TCS relay.
•
Analogues (current and voltage)
•
Phase failure relay
•
* If all circuit breakers on a switchboard are not fitted with electronic relays having adequate RS485 communications to the RTU
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Appendix N
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Typical ACCB Auxiliary Supply Arrangement
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Appendix O
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Protection Relay Labelling Guidelines
The following rules apply to the labelling of protection relays and associated auxiliary relays: •
LOCATION OF LABELS: •
•
•
Labels should be located above the relay. If this is not possible, then they should be located directly below the relay.
COLOUR OF LABELS: •
All protection relays labels shall have black writing on a yellow background.
•
All auxiliary relays (such as multi-trip relays) shall have black writing on a white background.
FORMAT •
To keep the length of labels to a minimum, abbreviations shall be used for the protection functions. The valid abbreviations are detailed in Table N1.
•
All labels are to be in CAPITALS (except for abbreviations such as “Tx” & “kV”).
•
The description of equipment shall be consistent with terminology as used in the AC operating diagrams. This is summarised below:
•
FEEDERS:
“Feeder ID” ;
Where “Feeder ID” is the unique 3 digit identification assigned to each high voltage feeder. •
TRANSFORMERS:
“Unit ID” + “voltage ratio” + “Tx” ;
Where “Unit ID” is the identification given where there are multiple transformers (eg. No.1, No.2 etc). “voltage ratio” is the voltage ratio of the transformer usually expressed in kV (eg. 33/11kV, 66/33kV). •
RECTIFERS:
“Unit ID” + “RECTIFIER”
Where “Unit ID” is the identification given where there are multiple rectifiers (eg. No.1, No.2 etc).
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•
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CONTENT:
FIRST LINE OF LABEL: The following sequence should be used to construct a label: 1)
Equipment being Protected/Monitored eg.
2)
Type of Protection eg.
3)
(HMB4), (P521), (HO4) (CDD31), (P127), (CRP7), (CR LE) (P632), (KBCH), (DDT)
Pointer to Relay (if needed) eg.
•
DOC & DE RELAY PW RELAY A∅ DOC RELAY A∅ OC RELAY FL RELAY Tx OC RELAY Tx DIFF RELAY
Make of Relay in Brackets. eg.
4)
No.1 RECTIFIER BUS ZONE 792 No.2 33/11kV Tx
↑ ↓
EXAMPLES OF LABELS: 798 DOC & DE RELAY (P127) 798 PW RELAY (P521) ↑ No.1 RECT IOC & IE RELAY (MCAG33) No.1 RECT IOC & IE BACKUP RELAY (P127) TRIP CCT 1 TCS RELAY (1TM10) No.1 33/11kV TxDIFF RELAY (P632) No.1 33/11kV Tx OC & E RELAY (P127) 1-2 BZT RELAY (MCAG34) ↓ 1-2 BZT MTM RELAY (MVAJ13) No.1 33/11kV Tx MTA RELAY (MVAJ11)
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No.1 SECTION BZ MTM RELAY (MVAJ13)
PROTECTION FUNCTION ARC DETECTION
ABBREVIATION AD
BUCHHOLZ
B
BREAKER FAIL
BF
BLOCKING RELAY
BRly
BACKUP
BU
BUS ZONE
BZ
BUS ZONE TIE
BZT
DIRECTIONAL EARTH FAULT
DE
DIRECTIONAL INSTANTANEOUS OVERCURRENT
DIOC
DIRECTIONAL OVERCURRENT
DOC
EARTH FAULT
E
DCCB FRAME LEAKAGE
FLDC
AC FRAME LEAKAGE
FL
RECTIFIER FRAME LEAKAGE
FLR
INSTANTANEOUS EARTH LEAKAGE
IE
INTELLIGENT GAS INFORMATION SYSTEM
IGIS
INTELLIGENT LIGHT INFORMATION SYSTEM
ILIS
INSTANTANEOUS OVERCURRENT
IOC
INTERTRIP
IT
INSTANTANEOUS & TIME DELAY OVERCURRENT
ITOC
MUTI TRIP RELAY – AUTOMATIC RESET
MTA
MULTI TRIP RELAY – MANUAL RESET (HAND)
MTM
NEUTRAL LEAKAGE
NL
OVERCURRENT
OC
LOW OIL
LO
OVERCURRENT & RESIDUAL EARTH FAULT INVERSE TIME PRESSURE SWITCH
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PROTECTION FUNCTION
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ABBREVIATION
PILOT WIRE
PW
DC REVERSE CURRENT
RC
TRANSFORMER DIFFERENTIAL
TxDIFF
TRANSFORMER WINDING TEMPERATURE
WT
TRIP CIRCUIT SUPERVISION
TCS
TRIP SUPPLY SUPERVISION
TSS
TABLE N1: Protection Function Abbreviations
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Appendix P
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Standard Current Transformer Configurations
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Appendix Q
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Protection Non-Compliances Particular to the ECRL Project
This appendix details known design issues relating to the protection schemes and equipment installed in the ECRL project that do not comply with the general requirements of this standard. These arrangements have been accepted for the ECRL project only.
Appendix Q.1 •
Bus-zone protection not installed on the 11kV switchboards, (blocking scheme installed in lieu).
•
Pilot wire protection not installed on the 11kV feeders.
•
Multi-trip relays not used.
•
Dual trip coils not installed.
•
Test blocks not wired in accordance with standard configuration.
•
Protection relays not programmed with standard configuration.
Appendix Q.2
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11kV Protection
33kV Protection
•
Multi-trip relays not used on the 33/11kV transformer protection (pushbutton installed to reset latched P632 output relays).
•
Dual trip coils not installed.
•
Test blocks not wired in accordance with standard configuration.
•
Protection relays not programmed with standard configuration.
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Discipline
Electrical Engineering Standard Category
General Title
Electrical Power Equipment - Integrated Support Requirements Reference Number
EP 00 00 00 12 SP Version
2.0 Date of Issue
JUNE 2007 Status
Approved
Copy No.
A coloured number in this space indicates that this document is controlled
Electrical Engineering Standard: General
Electrical Power Equipment - Integrated Support Requirements EP 00 00 00 12 SP
Prepared by
Neal Hook, Principal Engineer, Power Systems Engineering Standards & Services Division Neal Hook, Principal Engineer, Power Systems Engineering Standards & Services Division David Stuart-Smith, Chief Engineer, Electrical Systems Engineering Standards & Services Division
Reviewed by Approved by
Revision Summary
Version
2.0
Revision Date
21/06/2007
Authorised Details Name/Position
First Issue
Signature
NEAL HOOK Principal Engineer, Power Systems Engineering Standards & Services
See Revision History on page 11 for a full listing of the document changes.
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DISCLAIMER Rail Corporation of New South Wales has used its best endeavours to ensure that the content, layout and text of this document is accurate, complete and suitable for it’s stated purpose. It makes no warranties, express or implied, that compliance with the contents of this document shall be sufficient to ensure safe systems of work or operation. RailCorp will not be liable to pay compensation in respect of the content or subsequent use of this document for any other purpose than its stated purpose or for any purpose other than that for which it was prepared except where it can be shown to have acted in bad faith or there has been wilful default.
DOCUMENT APPROVAL The technical content of this document has been approved by the relevant RailCorp engineering authority and has also been endorsed by the RailCorp Configuration Management Committee directly or as delegated through the conditions of the Configuration Management Policy.
DOCUMENT SUPPLY and CONTROL The Primary Version of this document is the electronic version that is available and accessible on the RailCorp Internet and Intranet website. It is the user’s sole responsibility to ensure that they are only using the latest version of the document prior to its use. The approving section does not make controlled copies of this document available by any means other than on the aforementioned website. Controlled hardcopy versions of this document may be produced if they are registered using a local document management and distribution system. When controlled hardcopy versions are issued using a local document management system each copy is to be uniquely identified in the Control Box provided on the front of the document. The identifier used must identify the local distribution centre and the copy number. The identifier is to be marked using a colour other than black or grey.
COPYRIGHT The information in this document is Copyright protected. Apart from the reproduction without alteration of this document for personal use, non-profit purposes or for any fair dealing as permitted under the Copyright Act 1968, no part of this document may be reproduced, altered, stored or transmitted by any person without the prior written consent of RailCorp.
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About This Standard This document details the integrated support requirements common to most major electrical equipment in the RailCorp high voltage and traction networks. It is designed to be used in conjunction with RailCorp technical standards for individual electrical equipment and contains information to facilitate the support of the RailCorp asset management systems including maintenance management, configuration management, quality management, risk management and financial processes. To achieve best practice RailCorp is continually developing its asset support requirements related to its business objectives. This document will aid in the provision of information required to determine the full life cycle cost of electrical equipment through their acquisition, operational and disposal phases. The release of this document may affect the operation or maintenance of existing electrical equipment in the RailCorp high voltage or traction network. Where integrated support requirement work is undertaken on existing equipment it shall comply with this document.
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Table of Contents 1
Scope and Application............................................................................. 7
2
References................................................................................................ 8 2.1
Code of Practice ................................................................................................................8
2.2
Australian Standards.........................................................................................................8
2.3
Ex-RIC Standards ..............................................................................................................8
2.4
RailCorp Documents .........................................................................................................8
2.5
RailCorp Templates ...........................................................................................................9
3
Definitions and Abbreviations .............................................................. 10
4
Integrated Support Requirements ........................................................ 11 4.1
Integrated Support Objectives .......................................................................................11
4.2
Maintenance Requirements ............................................................................................11
4.2.1
Scheduled Maintenance
11
4.2.2
Maintenance Requirements Analysis (MRA)
12
4.2.3
Failure Modes, Effects and Criticality Analysis (FMECA)
12
4.2.4
Technical Maintenance Plan (TMP)
15
4.3
Spares Support ................................................................................................................17
4.3.1
Spares Assessment Methodology
17
4.3.2
Recommended Spares List
17
4.3.3
Packaging, Storage and Handling
18
4.4
Operation and Maintenance Manual ..............................................................................18
4.4.1
General
18
4.4.2
Submission of Documentation
23
4.4.3
Scope of Manual
25
4.4.4
Validation of Content
29
4.5
Training.............................................................................................................................29
4.5.1
Training Requirements
29
4.5.2
Operator Training
30
4.5.3
Maintenance Training
30
4.6
5
Facilities, Equipment and Special Tools .......................................................................31
Revision History ..................................................................................... 32 5.1
Version 1.1........................................................................................................................32
5.2
Version 2.0........................................................................................................................32
Appendix A
Technical Schedule................................................................................ 33
Appendix B
Request for Tender (RFT) Checklist ..................................................... 35
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Appendix B.1
Version: 2.0 Issue Date: JUNE 2007
General .............................................................................................................................35
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1
Scope and Application This document details the integrated support requirements common to most major electrical equipment in the RailCorp high voltage and traction networks. It is designed to be used in conjunction with RailCorp technical standards for individual electrical equipment and contains information to facilitate the support of the RailCorp asset management systems including maintenance management, configuration management, quality management, risk management and financial processes. To achieve best practice RailCorp is continually developing its asset support requirements related to its business objectives. This document will aid in the provision of information required to determine the full life cycle cost of electrical equipment through its acquisition, operational and disposal phases. The requirements of this document apply when a new piece of major electrical equipment is installed in the RailCorp high voltage or traction networks in conjunction with the relevant RailCorp standard for the equipment. The release of this document may affect the operation or maintenance of existing electrical equipment in the RailCorp high voltage or traction network. Where integrated support requirement work is undertaken on existing equipment it shall comply with this document.
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2
References 2.1
Code of Practice The following documents are either referenced in this standard or can provide further information.
2.2
Australian Standards The following Australian Standards are either referenced in this document or can provide further information.
2.3
2.4
Standard
Title
AS 1000
The International System (SI) units and their application
AS 1100
Parts 101 & 201 Technical Drawing
AS 1102
Graphical symbols for electrotechnical documentation
AS 1470
Health and Safety at work – Principles and Practices
AS 9001
Quality Systems – Model for Quality assurance in design/development, production, installation & servicing
Ex-RIC Standards Standard
Title
AM 9995 PM
RIC Maintenance Requirements Analysis Manual
EP 00 00 00 02 SP
Electrical Technical Maintenance Coding System
RailCorp Documents The following RailCorp documents are either referenced in this document or can provide further information. Document
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Title
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2.5
RailCorp Templates The following drawings form part of this specification. Use
Filename
FMECA
Blank FMECA sheet.xls
Service schedule(s)
Blank service schedule sheet.xls
TMP
Blank TMP sheet.xls
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3
Definitions and Abbreviations For the purpose of this specification the definitions specified in the referenced Australian Standards apply. Item
Description
Rotable item
A major item of equipment/item/component that may be removed from its operating position for scheduled maintenance and subsequently reinstalled or replaced with a serviceable equivalent.
Consumable item
A non repairable component which is damaged or wears due to use and is replaced with new component when necessary or where predetermined wear limits are reached, ( items such as contacts, lubricants, etc).
Repairable item
An equipment component which may be removed from its operating position for maintenance, restored to a predetermined serviceable condition and reinstalled for a further use, such as switchgear bushings, high speed circuit breaker.
Insurance spare
An equipment component purchased and stored as replacement component for use in repairing the systems to serviceable condition subsequent to the occurrence of a major incident that causes secondary damage, such as damage to OHW, train derailment and the like. Insurance spares are normally components that are susceptible to sustaining damage beyond economical repair if involved in an incident and/or, have excessive lead times for replacement, and are required to restore a system to service.
Maintenance requirements analysis (MRA)
Version: 2.0 Issue Date: JUNE 2007
The process of determining the range of tasks in the maintenance schedules that will preserve the inherent levels of reliability of the design and which provide an effective and efficient means of keeping the equipment in the condition required.
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4
Integrated Support Requirements 4.1
Integrated Support Objectives The information required to operate and maintain the equipment throughout the operational life, in a cost effective manner and to a level that is consistent with the planned operational performance and usage of the systems shall be developed and provided. This includes: •
Maintenance Requirements
•
Spares Support
•
Operations and Maintenance Manuals
•
Training, and
•
Support Equipment and Tooling
4.2
Maintenance Requirements
4.2.1
Scheduled Maintenance The planned maintenance requirements for the equipment shall be developed and provided. Planned maintenance requirements shall as a minimum include the following, to the extent applicable to the design: •
Pre-operating procedures.
•
Preventive maintenance, including service/lubrication tasks, condition monitoring requirements, scheduled restore/discard tasks, failure finding testing and any other tasks considered appropriate for all installed systems and equipment.
•
Recommended overhaul requirements, including the recommended overhaul interval and location (onsite/depot/service centre).
•
Details of any items subject to finite replacement or inspection lives, including structural inspections where applicable.
Maintenance checklists and procedures necessary to carry out the proposed tasks shall be defined. Maintenance checklists and procedures shall include information on consumable items used as part of the task and reference to any special tools, Version: 2.0 Issue Date: JUNE 2007
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facilities or equipment needed to perform the task as well as any special skills and/or training necessary for the task. The recommended maintenance requirements established as a result of this activity shall be documented in the form of a Technical Maintenance Plan – as defined in 4.2.4. 4.2.2
Maintenance Requirements Analysis (MRA) The MRA process shall be undertaken in accordance with the RailCorp Maintenance Requirements Analysis Manual AM 9995 PM, which is based upon a Failure Modes, Effects and Criticality Analysis (FMECA) and Reliability Centred Maintenance (RCM) methodology. (see below) The results of the MRA shall be documented and supplied. The Hazards and Occupational Health and Safety (OH&S) implications resulting from the MRA shall also be analysed and documented prior to completion of the respective sets of Service Schedules. The analysis and documentation shall be undertaken using either the OEM’s inhouse software tools, or the templates provided. Where in-house tools are used, hard and electronic copy of the analysis shall be provided in an agreed format to allow transfer of the information into the maintainer's systems.
4.2.3
Failure Modes, Effects and Criticality Analysis (FMECA) A Failure Modes, Effects and Criticality Analysis (FMECA) shall be completed, documented and supplied as part of the MRA. The FMECA serves to identify potential failure modes that must be considered as part of the reliability estimation process for a specific item and to provide information on those that should receive highest priority for reliability improvement. The FMECA also provides the basis for development of programmed maintenance requirements and for identifying failure modes and effects for consideration as part of the Safety program. The FMECA will be conducted down to the Lowest Replaceable Unit level. The FMECA process shall be completed and documented to either: •
RailCorp’s requirements as specified in the Maintenance Requirements Analysis Manual AM9995PM, or
•
the OEM’s standard, provided that the approach meets the basic objectives set out within the potential Failure Mode and Effect Analysis Handbook, which forms part of the set of documentation for the QS 9000 supplement to QS 9000 Quality Systems. The FMECA shall be documented using the OEM’s FMECA software tool.
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•
Potential or demonstrated failure modes for each significant item within the design. This will be carried out at the replaceable subassembly level.
•
The likelihood of failure for each identified failure mode, where possible expressed in terms of failure per million operating hours.
•
The effect of failure in terms of the impact on safety, operating performance, environmental impact and economic consequences, including damage to other equipment.
•
The criticality of failure in terms of operation of the system, that is, whether trains can continue to operate without delay or whether the rail systems/subsystem can continue to operate after the failure has occurred.
4.2.3.1 FMECA Worksheet documentation The following table provides definition of the information to be included in the FMECA.
Heading
Requirement
Item/Assemby, Part No and Drawing No.
Identify the asset, manufacturer's part identification, and drawing details
Analyst
Identify the analyst(s) who prepared the FMECA
Functional description.
Provide an overview description of the asset's function
MTBF (hrs)
Enter the asset/item's Mean Time Between Failure in hours
Function
Principal functions - which represent the business reason for an assets existence. Enter the item name and as concisely as possible the function(s) of the item to meet the design intent. Functions may also be identified in the form of a desired standard of performance with functional failure deemed to have occurred when this level of performance is not available. Include information regarding the environment in which the system operates. (eg, define temperature, voltage etc). Ancillary function - which provide additional useful functions either as enhanced capability, additional capability or opportunistic. Protective function - such as alarms and automatic shutdowns
Part
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The component part within the Item/Assembly which
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Heading
Requirement fails
Failure mode
Failure modes are the effects by which failures are observed. It includes the manner by which the failure is observed & is generally described by the way in which the failure occurs and its impact, if any, on the equipment operation. Ie broken, seized, excessive vibration.
Cause of Failure
Need to state the engineering mechanism of failure that leads to the particular functional or conditional failure. Failure causes are derived from the design. They are associated with the detailed design approach taken, the materials used, the operating environment including such information as physical loads and corrosive materials. Human factor information is also required, to support the allocation of warning notices in manuals or service schedules.
Local effects
Identify that impact a particular failure mode has on the operation, function or status of an item. The description of the failure effect must be adequately detailed to allow classification into one of the four categories of consequences: Hidden/safety/environment Evident/safety/environment Evident/economic Hidden/economic
Failure Rate
Identify the rate (in failures per million hours) at which this failure mode/cause combination occurs. If data is not available to establish exact rates, enter the indicative percentage (with % symbol) that this failure mode / cause combination represents out of the total failures
Tasks
Identify maintenance task which addresses the failure mode/cause. Needs to be split maintenance tasks into and “on” or “off” system. The maintenance task must fall into one of the following categories: Service / lubrication task Condition monitoring task include examinations for indications of conditional failure before they lead to functional failure Scheduled restoration or rework at some hard time conducts a schedule of maintenance tasks Scheduled discard which at some time removes an item
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Heading
Requirement from the system Failure finding task which is only applicable to hidden functional failures where a confidence check that the system is still operational is required at some interval to reduce the probability of multiple failures
Type
Identify type of Maintenance Task using the code letters on the worksheet.
Period
Frequency for the maintenance Task - time, operational count, operational event(s), etc Table 1 – FMECA worksheet
4.2.4
Technical Maintenance Plan (TMP) The recommendations resulting from the maintenance analysis process shall be documented in the form of a Technical Maintenance Plan (TMP) for the system using the RailCorp Service Schedule and TMP Templates. The TMP shall include details of: •
The equipment.
•
All scheduled maintenance activities for the equipment.
•
The intervals (periodicity) at which each maintenance schedule should be performed.
•
Skills and competencies for completion of each major task in the schedule. Note that for the purposes of the TMP a “task” may comprise a number of actions performed as part of a scheduled examination.
•
Recommended location at which the schedule is to be completed eg onsite, depot, workshop, central facility, etc.
•
Details of special facilities or equipment necessary for completion of the schedule.
•
Reference to technical data or inspection schedules required for completion of the task.
•
Checklists for recording the results of the maintenance processes.
The terminology used in the service schedule tasks shall be in accordance with 4.2.4.1. Refer to section 4.3.6 of AM 99 95 PM RailCorp Maintenance Requirements Analysis Manual for further details.
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4.2.4.1 Service Schedule standard terminology The words used to define maintenance actions shall be standardised to ensure consistency of approach and to assist the transfer of information across application boundaries. Consistency of task description enables the provision of a common interpretation of instructions and task directives by all support staff. Each task statement should have the standard structure shown at Figure 1 VERB
Examine
NOUN
CONDITIONAL STATEMENT
attachment blocks
for
security
Figure 1 - Standard task statement structure The verbs are the key words which define the task action and have a standardised description. The remainder of the statement will depend on the particular item and failure mode and hence use conventional English meanings. These key verbs are listed in Figure 2:
Verb
Detailed requirement
Examine
Carry out a visual survey of the condition of an item without dismantling (unless directed to do so by the maintenance instruction).
Lubricate
Apply a specified lubricant (e.g. oil type XYZ, grease type ABC) to a specified area of equipment (often specified in a separate lubrication chart).
Check
Make a comparison of a measurement of some quantity (e.g. time, pressure, temperature, resistance, dimension) to a known value (accept/reject criteria) for that measurement and if required rectify and/or replenish if necessary.
Check Operation or Operate
Ensure that an item of equipment or system functions correctly as far as possible without the use of test equipment or reference to a measurement.
Clean
Remove contaminating materials (e.g. dust, dirt, moisture, excessive lubricant) from an item of equipment.
Adjust
To alter as necessary to make an item compatible with system requirements.
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Verb
Detailed requirement
Test
Determine by using appropriate test equipment that a component of equipment functions correctly.
Replenish
Refill a container to a predetermined level, pressure or quantity and undertake associated access and closure tasks.
Fit
Correctly attach an item to another.
Refit
Fit an item that has been previously been removed.
Calibrate
Make a comparison of a measurement of time, pressure, temperature, resistance, dimension or other quantity to a known standard (usually a NATA laboratory function).
Disconnect
Uncouple or detach cables, pipelines or controls.
Reconnect
Reverse of disconnect.
Safetyseal
Securing of equipment which requires the breaking of a seal to manually operate (usually associated with emergency equipment).
Remove
Correctly detach one item from another.
Secure
To make firm or fast. Figure 2 - Task verbs - standard terminology
4.3
Spares Support
4.3.1
Spares Assessment Methodology The need for spare parts shall be assessed and the spare parts list developed using a clearly defined methodology. The methodology shall use established failure rates and the related maintenance policies, and identify the range and quantity of spares to be made available at any time to maintain the systems and ensure they meet the availability requirements. The need for insurance spares to meet unplanned needs shall be addressed, and a separate assessment process used to identify, quantify and list these insurance spares. The methodology to be used for the assessment of spares requirements must be included in the Maintenance Plan.
4.3.2
Recommended Spares List A recommended spares list shall be developed and provided. The recommended spares list must define the recommended range and quantity of
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rotable and repairable items, consumables and insurance spares to support the planned operational usage with the recommended maintenance policies. The recommended spares list shall be developed and refined during the design and construction of the equipment. The recommended spares list shall include the following information:
4.3.3
•
item identification (name, manufacturers part or reference number and specification, as appropriate);
•
recommended spares quantities;
•
expected price;
•
source;
•
procurement lead time;
•
failure rate;
•
number of items installed in the equipment
•
predicted usage rate and whether the item is consumable or is used in support of scheduled preventative maintenance; and
•
probability of the required item being available based on the recommended spares quantity and procurement lead time.
Packaging, Storage and Handling The requirements for packaging, storage and handling shall be provided for all recommended spares.
4.4
Operation and Maintenance Manual
4.4.1
General An Operations and Maintenance Manual shall be provided for the equipment, and shall meet the requirements below. The manual shall be delivered in hard copy and in electronic format. (see below). Manuals may be produced to meet the specification below, or supplied as standard manuals in the OEM’s proprietary format, provided that the information required in 4.4.3 below is clearly contained within the combination of manuals, and any attachment. Manuals shall only contain information about the equipment supplied. Where the OEM’s proprietary manuals contain information and references to multiple models of equipment, information relating to unsupplied equipment shall be clearly crossed or blanked out.
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Hard copies of the manual shall have the following features:
Binding •
Bound; or
•
Contained in white, durable, four ring hard cover binders, not greater than 50 mm thick, with the facility, equipment or plant identification permanently marked on the spine and outside cover with clear protection on the covers. Binders shall not be filled to more than 60% capacity.
Paper •
Not less than 80 gsm in weight, surface sized and suitable for offset/laser printing, in double-sided form;
•
Text on A4 pages
•
Illustrations on A3 size paper folded to A4 size
Typeface and layout •
Clear typeface;
•
35 mm margin for binding;
•
Each section shall start on a right hand side page;
Organisation •
Divide sections with indexed plastic divider sheets ;
•
Protect vulnerable and much used pages with plastic covers;
•
Index the contents
•
Locate illustrations and at the rear of the text. Small illustrations, to highlight matters, may be located in the text;
•
Commence each document with a title sheet detailing as a minimum:
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1)
Name of System/Element/Item/Equipment;
2)
Supply Contract Details (if applicable);
3)
Name of Supplier (if applicable);
4)
Address for Service Calls (if applicable), and
5)
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The electronic form of the document shall be delivered in two forms: •
Microsoft Word97 format (for custom produced manuals),
•
PDF File(s), with all headings down to level 3 linked to the appropriate page/section in the pdf file(s). The PDF files shall also include pdf versions of OEM information, Works/Test certificates and other hardcopy documents to produce a pdf version of the entire manual. Clear scanned images with a resolution for legibility incorporated into pdf files are acceptable. When the individual pdf files are generated they shall not be password protected, and shall be enabled for editing to enable the pdf file size to be reduced where required for more efficient intranet access. Or Approved equivalent appropriate industry standard software as may be appropriate at the time of delivery of this documentation
4.4.1.1 Word Processor Configuration for Custom Produced Manuals 4.4.1.1.1 Text Styles and page settings The following settings and styles shall be used to produce the printed pages of the manual. Page Size Margins
A4 Top
2 cm
Bottom
2 cm
Left
2 cm
Right
2 cm
Header (from edge)
1.25 cm
Footer (from edge)
1.25 cm
Gutter
1.5 cm
Text Styles Heading 1
Arial, 14pt Bold, indent: hanging 2.06cm, paragraph spacing 12pt before, 6pt after, outline numbered, level 1
Heading 2
Arial, 12pt Bold, indent: left 1.25cm, hanging 1.73cm, paragraph spacing 6pt before, 6pt after, outline numbered, level 2
Heading 3
Arial, 12pt, indent: left 1.25cm, hanging 1.73cm,paragraph spacing 6pt before, 3pt after, outline numbered, level 3
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Heading 4
Arial, 12pt, italic, indent: left 1.25cm, hanging 1.73cm, paragraph spacing 6pt before, 3pt after, outline numbered, level 4
Normal
Arial, 11pt, indent left 2.0cm, paragraph spacing 6pt before and after, line spacing (at least) 12 point.
Table text
Arial, 11pt, left indent 0.1cm, right indent 0.1cm paragraph spacing 1pt before and after, line spacing (at least) 12 point.
Caption
Arial, 8pt, bold, centred, paragraph spacing 3pt before and after.
Warning
Normal + indent left 3.0cm, indent right 2.5cm
Header
Arial, 10pt italic, Tabs:9cm centred, 15.5cm right flush
Footer
Arial, 10pt italic, Tabs:9cm centred, 15.5cm right flush
4.4.1.1.2 Table of Contents The table of contents for the manual shall commence on page iii of the document and the table shall be created from style heading levels 1 to 4 inclusive. It shall be followed by a list of Figures and a list of Tables. 4.4.1.1.3 Page Numbering The introductory pages of the manual shall be numbered consecutively in roman numerals (i, ii, iii, iv etc). Each section of the manual shall be consecutively numbered in Arabic numerals, and be presented as ‘page x of y’, where y is the number of pages in the section of the manual. The introductory pages shall include the title page, Revision Control Table (see 6.1) and table of contents. 4.4.1.1.4 Numbering methodology The sections and subsections of the manual shall be outline numbered. Sections shall be numbered sequentially from 1.0 and shall be style ‘Heading 1’ Subsections shall be numbered sequentially within the section from n.1 and shall be style ‘Heading 2’ The section and subsection titles are listed in 4.4.3.
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Tables may be used to where applicable to simplify the presentation of information and data interpretation. Tables shall be numbered sequentially within each section using Arabic numerals in the order they appear in the text. Table numbering shall be of the form ‘Table n-1’ where n is the section number and it shall prefix the title of the Table. The figure text shall be style ‘caption’. The text within the tables shall be of style ‘table text’. Figures shall be numbered sequentially within each section using Arabic numerals in the order they appear in the text. Figure numbering shall be of the form ‘Fig. n-1’ where n is the section number and it shall prefix the title of the figure. The figure text shall be style ‘caption’. 4.4.1.1.5 Page header The header shall be formatted as style ‘header’ and shall have a 1 pt border line below the header paragraph. The content of the header lines of each section shall be:Line 1 Manual Title
Left flush
Section Name
at Tab 9 cm, centred
Manual Number
at Tab 15.5 cm, right Flush
Line 2 Section Revision Date
Left flush
Section Revision Number
at Tab 15.5 cm, right Flush
4.4.1.1.6 Page Footer The footer shall be formatted as style ‘footer’ and shall have a 1 pt border line above the footer paragraph. The content of the footer lines of each section shall be:© Rail Infrastructure Corporation
Left Flush
‘Section n - page x of y’
at Tab 15.5 cm, right Flush
4.4.1.1.7 Warnings and Cautions Where it is essential for the protection of the staff and / or equipment the manuals shall include the appropriate Warnings, Cautions and notes. The format of the text shall be style ‘ Warning’. The content of a warning box shall not be split over two pages. Warnings and cautions shall not contain procedural steps, nor be numbered. Where the warning or caution contains more than one critical element, those elements should be separated by the use of bullet points for each separate element.
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Warning shall be used for the protection of staff, Caution used for the protection of the equipment, and Note used to draw attention special requirements. Where a combination of warning, caution or note appear together they shall appear in the order of Warning, Caution then Note as applicable. 4.4.2
Submission of Documentation Operation and Maintenance Manuals shall be provided and be written in clear, concise English, produced in the format outlined above, and covering the following scope and content.
4.4.2.1 Document Numbering The number format shall be AA aabbcc ZZ, where: •
AA is the relevant discipline code from the RailCorp TMP,
•
aabbcc represent the next three layers of the RailCorp Technical Maintenance Code (TMC), and
•
ZZ is “MP” for a manual covering a system or subsystem, or “EQ” where the manual covers only one equipment group.
Refer to EP 00 00 00 02 SP “Electrical Technical Maintenance Coding System”. Revision numbers for draft versions of the Manuals shall be A, B, C etc. Revision numbers for approved versions of the Manuals shall be 1, 2, 3 etc. The document number shall be unique and shall be registered in the RailCorp master list of document numbers prior to document development commencing. 4.4.2.2 Inclusion of Drawings and Photographs Figures and/or pictures should be included where appropriate to complement the manual text. They shall be used to: •
Present information difficult to describe by text alone;
•
Provide identification of tools, parts etc;
•
Halftone figures (photographs) where used, shall be suitable for electronic scanning and photocopying without loss of detail.
4.4.2.3 Folders Where required the contents of the manual may be spread over multiple folders. Each folder shall be called a Volume. Where volumes are utilised, a complete table of contents for the entire manual shall be included in each volume, clearly indicating which sections are located in each volume.
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4.4.2.3.1 Covers and Spines The cover page for each volume shall be inserted as the first page within each volume, and a copy inserted into the front cover of the volume. The spine shall contain the Manual Identification Number, the volume number, and the numbers of the sections in the respective volume where the manual is split over more than one volume. The text shall be sized to suit the thickness of the folder. The spine identification box shall be positioned 5 cm from the top edge of the folder 4.4.2.3.2 Revision History The revision history of the manual shall be included in a Revision Control Table on page ii of the Operations and Maintenance Manual. See following sample page for layout of revision control tables. Sample Revision Control Table Page.
Revision Control Table Revision
Date of Approval
Summary of change
1
Sept 2002
Original Issue
2
Dec 2002
Section 4.3 revised
Current Subsection Revision Subsection
Current Revision
Summary of change
Title page
1
Original Issue
Revision Control
2
Table of Contents
2
1.0
1
Original Issue
2.0
2
Updated description of HV circuit breakers
3.0
1
Original Issue
4.0 – 4.2
1
Original Issue
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4.4.3
Subsection
Current Revision
Summary of change
4.3
2
Updated alarm test procedure
4.4-4.5
1
Original Issue
5.0
1
Original Issue
6.0
1
Original Issue
7.0
1
Original Issue
8.0
1
Original Issue
Scope of Manual The following information shall be included (where applicable) in the general order detailed below, in separate Operation and Maintenance Manuals for separate operable systems, types of items, geographic areas and the like.
Section 1
Purpose of the Manual 1.1 Brief description of the Manual’s purpose, structure and content. 1.2 References and associated publications and standards. 1.3 Definitions.
Section 2
Equipment Description 2.1 Physical Description of equipment and major components. 2.2 Principles and theory of operation. This section should explain enough so that fault finding can be sensibly carried out. Line type illustrations are appropriate. Summary of the key Design Parameters of the various elements of the equipment that need to be known in its operation, maintenance and management. A basic working description, including features and any automatic control, operational purposes and functions of the components, systems and items. For software oriented systems, functional specifications (hardware and software), systems programs, individual program modules, including flow charts and source codes, and the like. 2.3 Detailed component description. Each major component illustrated and described. 2.4 Operating Instructions and Procedures. Comprehensive details of technical information relevant to modes of operation with
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a step by step procedure arranged into sections, such as: Safety Procedures and inherent hazards to be documented including applicable material safety data sheets. This information will be used as input for Job Safety Analysis and pre work briefing. The JSA and pre work briefing to be undertaken by RailCorp; Operating ratings and limitations due to temperature, pressure and flow, or other relevant factors; Checks before, and procedures for, Equipment Startup, Operations and Shutdown; Emergency Shutdown and Abnormal Operation; Full information on alarm and trip settings; Full details on condition monitoring capability including accept/reject criteria Links to inspection, servicing and maintenance schedules as defined in the Maintenance Plan; Any other information needed by operating staff to ensure the safe and efficient operation of the equipment. Section 3
Operational and functional checks Describe the tests required to confirm operation and whether the equipment and its components are functioning within acceptable limits. Specify accept and reject limits and tolerances.
Section 4
On system maintenance Refers to maintenance carried out on the installed site. 4.1 List of tasks; 4.2 Tools and materials; 4.3 Maintenance tasks. Comprehensive step by step instructions in preventative and corrective maintenance procedures, nominating the work to be carried out by qualified tradespersons and others Safety procedures Maintenance standards Maintenance instructions for each of the service periods. Location of maintenance action (on-system, workshop etc). Consumables and special tools required. List of recommended greases and oils, stating quantities, methods and frequency for application.
Section 5
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Fault diagnosis
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Describe a series of sequential actions to diagnose equipment faults. It is important that the operational requirements are included in these sequences. Troubleshooting instructions in tabular form listing “fault”, “possible cause” and “remedial action”, with testing regimes and instructions. Section 6
Removal and Installation Describes procedure for transport, installation, commissioning or removal of the equipment or components. It shall include information on support equipment, packaging, handling, transport and storage requirements.
Section 7
Overhauling Step by step instructions and procedures for complete overhauls, indicating those procedures to be carried out by qualified tradespersons, described under at least the following subheadings: Material safety data Sheets Handling precautions Dismantling Cleaning, Inspection, Repair and Adjustment Reassembly Final Checks and Unit Running
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Section 8
Spare Parts Data on spare parts supplied under the following headings:“List of Suppliers”, stating: Manufacturer Manufacturer’s nearest representative Company address Telephone and Facsimile numbers “Illustrated Parts List”, including: A list (or lists) of parts with part numbers referenced to an illustration, preferably an exploded view of sectional drawing and a specification “Recommended Spare Parts”, including: The list of recommended spare parts with part numbers and quantities and a separate list of spare parts supplied under this Contract to the Principal’s Representative “Availability of Spare Parts”, including: A short statement quoting the worst case procurement lead time/availability to suit the quantities of parts from suppliers “Ordering Information”, including: Specific details that would be required when ordering replacement parts, such as serial number, model number, name, reference number and the like “Special Tools”, including: A list of any special tools required when for periodic maintenance or overhauls
Section 9
References Summary tabulation and details of all applicable Certificates, Warranties and Guarantees related to the asset with cross reference to the location of the originals. (Originals of all Certificates, Warranties and Guarantees must be provided as handover documentation, in a logical grouping for particular assets, labelled in such a manner as to provide traceability.) Tabulation of Consultants, Sub-Consultants, Service providers, Suppliers and other Subcontractors and utilities/service providers,
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together with contact details for each significant element of the assets. Reference to all commissioning records/results and reports. Section 10
Quality Records This section shall provide details and the respective forms (where required) of all records that are required for maintenance and breakdown actions. These shall be presented in tabular form, and sample forms produced one form per page in the manual. Each form shall be delivered in a separate file of native format (eg. MS Word or MS Excel)
Section 11
Test Certificates All works and site test/commissioning certificates for the system/ subsystem and equipment shall be included in this section.
Section 12
Hard copy of Work-as-Executed Drawings This section shall include a complete list of the drawings associated with the manual. The PDF version of the manual shall link to a PDF or TIFF copy of the each corresponding drawing.
4.4.4
Validation of Content The operations and maintenance documentation provided must be validated prior to commissioning and used as part of the training provided by the OEM.
4.5
Training
4.5.1
Training Requirements A training program shall be developed, provided and implemented. This shall cover each part of the equipment as specified by the RFT and address the following issues for each training course: •
specific training objectives;
•
training methods for the operation and maintenance personnel;
•
training documentation, aids and material necessary to support the training;
•
training syllabus, course outlines, training notes, content plans, in the form of a training manual, meeting the defined training course objectives;
•
cover both operations and maintenance requirements including testing and operational evaluations.
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The training shall be designed for appropriately qualified personnel requiring only specialised training required on the relevant systems. The training shall be conducted only by persons who are appropriately skilled, qualified, experienced and competent in the field involved, and who have completed formal training in instruction techniques. All training aids and material must be up to a good commercial standard and appropriate for the training to be conducted. Training may be conducted on a site where the equipment is installed or off-site. The required location for training will be stated in the RFT. Where training is to be conducted off-site and access to particular equipment is required, training must be undertaken on equivalent duplicate equipment to that installed on RailCorp’s network. Off site training must be supplemented with visits to the applicable installed system on the Site. If no location for off-site training is specified in the RFT, off-site training shall be provided in Sydney. 4.5.2
Operator Training The training program shall cover and address operations and site familiarisation training for electrical operators who will be required to operate, isolate and earth electrical equipment: The operator training shall be designed for persons qualified under the RailCorp Electrical Safety Instructions and experienced in the operation of existing electrical High and Low voltage infrastructure that is part of the Sydney railway network. The training shall include the:
4.5.3
•
theory and practice of the operation of the equipment and its constituent parts and systems;
•
controls and instruments;
•
safety and emergency operations; and
•
techniques for checking, testing and adjusting systems.
Maintenance Training Specific maintenance training shall be included for personnel responsible for: •
routine examination and servicing;
•
repair systems, including the temporary and permanent repair of damage caused through vandalism, collision or other unscheduled event; and
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•
specialist processes such as on site fault finding, removal and replacement, functional or operational testing to a level necessary to support the systems involved.
Maintenance training shall include familiarisation with the equipment, and the specific maintenance requirements for all system, subsystem and ancillary equipment arrangements. Maintenance training shall also cover the engineering management of the systems for engineering staff.
4.6
Facilities, Equipment and Special Tools A list of special tools, facilities and equipment necessary for the operation and maintenance of the systems shall be developed and provided. The list shall: •
include the recommended number of special tools, facilities and equipment required for the operation and maintenance of the equipment;
•
identify the items required to perform specific maintenance, repair and recovery tasks on the equipment, including scheduled preventative maintenance of the equipment, the removal, installation and testing of rotable and repairable items, and other procedures, such as temporary repairs during normal operating periods for unscheduled failures with follow-up maintenance and emergency recovery; and include any special purpose test equipment and facilities needed in support of the maintenance tasks, including specialist hand-tools.
This list of special tools, facilities and equipment must include: •
details of, and a specification for, each item;
•
purpose of the item;
•
maintenance requirements for each item,
•
supplier;
•
the quantity required;
•
price and validity period expected;
•
packaging, storage and handling requirements; and
•
delivery times.
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5
Revision History 5.1
Version 1.1 •
5.2
Added to Appendix A 4.2.1Scheduled Maintenance the requirement at tender stage to provide a preliminary list of scheduled maintenance and methodology to facilitate life cycle costing assessment.
Version 2.0 •
Version: 2.0 Issue Date: JUNE 2007
Updated to RailCorp Standards formatting. Changed hyperlink from 3.3.3 to 3.4.2
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Appendix A
Technical Schedule
The Tenderer shall supply the information listed in this Technical Schedule at tender stage. This information will be used as an aid to assess the life cycle cost of each tender and to confirm that tenderers understand the importance of the integrated support requirements in the procurement process. 4.2.1 Scheduled Maintenance Provide details of a preliminary scheduled maintenance list including methodology for this list.. 4.2.2 Maintenance Requirements Analysis (MRA) What analysis and documentation tools are to be used?
RailCorp templates or OEM’s in house software If OEM’s in house software is used please provide details of documentation and past usage.
Provide details of experience with MRA/RCM analysis and documentation. 4.2.3 Failure Modes, Effects and Criticality Analysis (FMECA) What method of FMECA will be used?
RailCorp templates or OEM’s in house software If OEM’s in house software is used please provide details of documentation and past usage.
What is the source and extent of the data used in the FMECA – provide detail. Is the FMECA based on operational experience – provide detail. 4.3.1 Spares Assessment Methodology What methodology for spares assessment will be used?
Please provide details of documentation and past usage.
Provide details of a preliminary spares list including methodology for this list. 4.3.3 Packaging, Storage and Handling Any special requirements for packaging, storage and handling for the equipment or recommended spares to be provided. 4.4 Operation and Maintenance Manual What format are the manuals to be supplied?
Microsoft Word97 format or OEM proprietary format modified to meet all requirements of section 4.4.3 of this standard. If OEM’s format is used please provide
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details of documentation and past usage. 4.5 Training Please provide details of anticipated delivery method, location, qualifications (technical and training) of personnel and list of resources.
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Appendix B
Request for Tender (RFT) Checklist
Appendix B.1
General
Where this standard is used as a supporting document for the integrated support requirements for the procurement of a major item of electrical equipment, the following information must be considered for the particular situation, and provided to the tenderers if required. All the items listed in this document may not be required. The Request for Tender must be specific in highlighting which clauses are mandatory, which clauses are optional and which clauses can be deleted. The following issues must be considered in making these determinations for each RFT: •
Previous usage of identical or similar equipment in the RailCorp network;
•
The number of items of equipment; and
•
The planned geographical spread of the equipment in RailCorp network;
•
The complexity of equipment;
•
The cost of equipment;
•
The cost of the total order.
Maintenance Requirements The RFT must indicate that the equipment supplier must provide all of the information set out in clause 4.2 Maintenance Requirements. The tenderer should also be made aware that if they are successful they must submit the FMECA at least 28 days prior to the delivery of the equipment; Spares Support The RFT must indicate that having completed the spares assessment methodology of clause 4.3 Spares Support the equipment supplier must provide the Recommended Spares List as set out in clause 4.3.2. The tenderer shall provide a preliminary spares list, refer to Appendix A Technical Schedule both in the equipment standard for the particular item of electrical equipment and this document. The decision for the procurement of spares is an iterative process and should be addressed as such by the RFT. Once the successful tenderer has provided the detailed spares list (which should be consistent with the original proposed spares list provided as part of the tender) and methodology, a RailCorp representative must then review the life cycle cost analysis in conjunction with the existing RailCorp spares. Note that it is a RailCorp responsibility to determine the system spares policy. Version: 2.0 Issue Date: JUNE 2007
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Packaging, Storage and Handling The RFT must indicate that the equipment supplier must provide all of the requested information in clause 4.3.3 Operation and Maintenance Manual The document number, as described in clause 4.4.2.1 Document Numbering, must be supplied to the successful tenderer. The successful tenderer must: •
submit two unbound draft hard copies of the Operations and Maintenance Manual at least 28 days prior to the delivery of the equipment;
•
ensure the draft manuals must meet all the formatting requirements of clause 4.4
•
act on comments made on, and correct deficiencies in, the draft copies and supply the final bound hard copy sets and electronic sets incorporating all the changes needed by the equipment delivery date;
The number of hard copies of the manual shall be a minimum of five (5) (or 1 each location if required, 1 each field engineering office, 1 for Design) and the number electronic versions on CD shall be two (2) (or 1 each field engineering office, 1 for Design). The RFT must specify total hardcopy required. Training For the tenderer to determine the training requirements of clause 4.5 Training, the tenderer must be informed of the number of staff nominated for each type of training. The RFT must indicate that the equipment supplier must provide the training program and training manual for review at least 28 days before any training takes place. The RFT must nominate location for on-site, and off-site training to be delivered. Refer to clause 4.5.1. Facilities, Equipment and Special Tools The RFT must indicate that the equipment supplier must provide the list of special tools, facilities and equipment as set out in clause.4.6 A final list of special tools, facilities and equipment shall be submitted not later than 28 days prior to delivery of the first installation or in sufficient time for essential items to be available for use with training, whichever is the earlier. The RFT must specify details of the process to procure the range of special tools, facilities and equipment required following the submission and review of the recommended list. Refer to clause 4.6. Version: 2.0 Issue Date: JUNE 2007
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The RFT must indicate that the tenderer must provide a preliminary list of special tools, facilities and equipment with the tender. Quantity and Costing of Integrated Support Deliverables The RFT shall state the quantity of each deliverable required and request a breakdown of the cost for the various items to facilitate the full life cycle cost analysis. The list of deliverables to be costed shall include: •
Provision of Operations and Maintenance manuals in accordance with clause 4.4;
•
Provision of training aids and material for the Principal’s use in undertaking future training.
Provision of training in accordance with clause 4.5. The training costs are to be broken down into separate costs for Operator Training and Maintenance Training.
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Discipline
Electrical Engineering Standard Category
General Title
Common Requirements for Electric Power Equipment Reference Number
EP 00 00 00 15 SP Version
2.0 Date of Issue
JUNE 2007 Status
Approved
Copy No.
A coloured number in this space indicates that this document is controlled
Electrical Engineering Standard: General
Common Requirements for Electric Power Equipment EP 00 00 00 15 SP
Prepared by
Neal Hook, Principal Engineer, Power Systems Engineering Standards & Services Division Neal Hook, Principal Engineer, Power Systems Engineering Standards & Services Division David Stuart-Smith, Chief Engineer, Electrical Systems Engineering Standards & Services Division
Reviewed by Approved by
Revision Summary
Version
2.0
Revision Date
01/06/2007
Version: 2.0 Issue Date: JUNE 2007
Authorised Details Name/Position
First Issue
Signature
NEAL HOOK Principal Engineer, Power Systems Engineering Standards & Services
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DISCLAIMER Rail Corporation of New South Wales has used its best endeavours to ensure that the content, layout and text of this document is accurate, complete and suitable for it’s stated purpose. It makes no warranties, express or implied, that compliance with the contents of this document shall be sufficient to ensure safe systems of work or operation. RailCorp will not be liable to pay compensation in respect of the content or subsequent use of this document for any other purpose than its stated purpose or for any purpose other than that for which it was prepared except where it can be shown to have acted in bad faith or there has been wilful default.
DOCUMENT APPROVAL The technical content of this document has been approved by the relevant RailCorp engineering authority and has also been endorsed by the RailCorp Configuration Management Committee directly or as delegated through the conditions of the Configuration Management Policy.
DOCUMENT SUPPLY and CONTROL The Primary Version of this document is the electronic version that is available and accessible on the RailCorp Internet and Intranet website. It is the user’s sole responsibility to ensure that they are only using the latest version of the document prior to its use. The approving section does not make controlled copies of this document available by any means other than on the aforementioned website. Controlled hardcopy versions of this document may be produced if they are registered using a local document management and distribution system. When controlled hardcopy versions are issued using a local document management system each copy is to be uniquely identified in the Control Box provided on the front of the document. The identifier used must identify the local distribution centre and the copy number. The identifier is to be marked using a colour other than black or grey.
COPYRIGHT The information in this document is Copyright protected. Apart from the reproduction without alteration of this document for personal use, non-profit purposes or for any fair dealing as permitted under the Copyright Act 1968, no part of this document may be reproduced, altered, stored or transmitted by any person without the prior written consent of RailCorp.
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About This Specification This document details the common requirements for electric power and control cubicles or assemblies forming part of switchgear, rectification equipment, transformers and similar equipment deployed in the Electric Power sub-system of RailCorp. It includes requirements relating to the equipment as a whole and components used in the equipment, to both hardware and software aspects and also the data set associated with the equipment. The requirements of this document apply to new power and control cubicles or assemblies as well as existing equipment that is modified or refurbished. It is intended that this document be called up in other documents and these requirements only apply when this document is referred to in the primary specification for the equipment.
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Table of Contents 1
Scope and Application............................................................................. 7
2
Normative References ............................................................................. 8 2.1
Code of Practice ................................................................................................................8
2.2
International Standards.....................................................................................................8
2.3
Australian Standards.........................................................................................................8
2.4
RailCorp Documents .........................................................................................................9
2.5
RailCorp Templates ...........................................................................................................9
3
Technical Requirements........................................................................ 10 3.1
Panels and Doors ............................................................................................................10
3.2
Painting.............................................................................................................................10
3.2.1
Indoor Equipment
10
3.2.2
Outdoor Equipment
10
3.3
Cable Entry.......................................................................................................................11
3.4
Access ..............................................................................................................................11
3.5
Lifting Points....................................................................................................................11
3.6
Fixing Points ....................................................................................................................11
3.7
Colour Convention for Controls and Indications .........................................................11
3.7.1
1500V and High Voltage Devices
11
3.7.2
Low Voltage Devices
12
3.8
Equipment Mounting .......................................................................................................12
3.9
Labelling ...........................................................................................................................12
3.9.1
Language
12
3.9.2
Equipment Labels
12
3.9.3
Terminal Strip Labels
13
3.9.4
Wire Identification & Numbering
13
3.9.5
Cable identification codes for schematics, cable schedule and drawings
13
3.10
Auxiliary Supply Voltage.................................................................................................14
3.10.1
Traction Substation – DC auxiliary supply
14
3.10.2
Traction Substation – AC auxiliary supply
15
3.10.3
DC auxiliary supply – other than traction substations
15
3.10.4
AC auxiliary supply – other than traction substations
15
3.11
Wiring................................................................................................................................15
3.11.1
General
15
3.11.2
Termination
16
3.11.3
Minimum Wire Size and Wire Type
16
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3.11.4
Wire Colours
16
3.12
Terminal Blocks ...............................................................................................................16
3.13
Earth terminal...................................................................................................................17
3.14
Light ..................................................................................................................................17
3.15
Auxiliary Relays, Push Buttons, and Selector Switches .............................................17
3.15.1
Contacts
17
3.15.2
Relays
17
3.15.3
Suppression Diodes
17
3.15.4
Trip Circuit Supervision
17
3.15.5
Indicator Lights
18
3.16
Programmable Equipment ..............................................................................................18
3.17
Current Transformers......................................................................................................18
3.18
Metering ............................................................................................................................18
3.19
Selection of Components and Equipment ....................................................................19
3.20
Environmental..................................................................................................................19
4
Maintenance Concept ............................................................................ 20
5
Testing .................................................................................................... 21 5.1
Type Tests ........................................................................................................................21
5.2
Routine Tests ...................................................................................................................21
6
Data Set Associated With The Equipment ........................................... 22 6.1
Drawings...........................................................................................................................22
6.1.1
Drawings Required
22
6.1.2
Manufacturers Standard Drawings
23
6.1.3
Project Drawings
23
6.2
Test Results .....................................................................................................................25
7
Appendices............................................................................................. 26
Appendix A
Schematic Diagram Identifiers.............................................................. 27
Appendix B
Request for Tender Checklist ............................................................... 31
Appendix B.1
Application .......................................................................................................................31
Appendix B.2
Information to be supplied to the Tenderer ..................................................................31
Appendix B.3
Information to be provided by equipment suppliers ...................................................33
Appendix B.3.1 Label Schedule
33
Appendix B.3.2 Inspection and Test Plan
33
Appendix B.3.3 Drawings
33
Appendix C
Version: 2.0 Issue Date: JUNE 2007
AutoCAD to Microstation Specifications ............................................. 35
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1
Scope and Application This document details the common requirements for electric power and control cubicles or assemblies forming part of switchgear, rectification equipment, transformers and similar equipment deployed in the Electric Power sub-system of RailCorp’s infrastructure. It includes requirements relating to the equipment as a whole and components used in the equipment, to both hardware and software aspects and also the data set associated with the equipment. The requirements of this document apply to new power and control cubicles or assemblies as well as existing equipment that is modified or refurbished. The standard RailCorp relay and circuit naming conventions are included at Appendix A. The release of this document will not affect the operation or maintenance of existing power and control cubicles or assemblies in the RailCorp network.
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2
Normative References 2.1
Code of Practice The following documents contain provisions that, through reference in this text, constitute provisions of this specification. At the time of publication, the editions indicated were valid.
2.2
2.3
International Standards Standard
Title
IEEE C.37.2 -1996
Standard electrical power system device function numbers and contact designations.
Australian Standards The following Australian Standards are either referenced in this document or can provide further information. Standard
Title
AS 1042 – 1973
Direct-acting Indicating Electrical Measuring Instruments and their Accessories. (Withdrawn)
AS 1102 – 1997
Graphical symbols for Electrotechnical Documentation
AS 1675 - 1986
Currrent Transformers - Measurement and Protection
AS 60044.1 – 2007
Instrument Transformers – Current Transformers.
AS 1939 Supp 1 – 1990
Degrees of protection provided by enclosures for electrical equipment (IP Code) – Wallchart 1
AS 1939 Supp 2 – 1990
Degrees of protection provided by enclosures for electrical equipment (IP Code) – Wallchart 2
AS 2067 – 1984
Switchgear assemblies and ancillary equipment for alternating voltages above 1 kV
AS 2700 – 1996
Colour Standards for General Purposes.
AS/NZS 3000 – 2000
Electrical Installations (known as the Australian/New Zealand Wiring Rules)
AS/NZS 3439.1 – 2002
Low-voltage switchgear and controlgear assemblies – Type-tested and partially type-tested assemblies.
AS/NZS 5000.1 –
Electric cables – Polymeric insulated – For working
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2.4
Standard
Title
2005
voltages up to and including 0.6 / 1 (1.2) kV
AS/NZS 5000.2 – 2006
Electric cables – Polymeric insulated – For working voltages up to and including 450/750 V
AS/NZS 5000.3 – 2003
Electric cables – Polymeric insulated – Multicore control cables
AS 60038 – 2000
Standard voltages
AS 60529 – 2004
Degrees of protection provided by enclosures (IP Code)
RailCorp Documents The following RailCorp documents are either referenced in this document or can provide further information.
2.5
Document
Title
EP 00 00 00 12 SP
Electrical Power Equipment – Integrated Support Requirements
EP 00 00 00 13 SP
Electrical Power Equipment – Design Ranges of Ambient Conditions
EP 19 00 00 02 SP
Protection System Requirements for the High Voltage Network
ED 0022P
CAD and Drafting Manual – All Design Areas
ED 0024P
CAD and Drafting Manual – Electrical
RailCorp Templates The following templates are provided for documentation: Use
Filename
Cable schedule
Blank Cable schedule.xls
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3
Technical Requirements 3.1
Panels and Doors All panels, including doors, shall generally be constructed of mild steel sheet with robust steel framework sufficiently braced to prevent warping and twisting. The minimum sheet thickness shall be 1.2 mm for panels and 1.6 mm for doors. Other materials such as aluminium and stainless steel may be used subject to RailCorp approval. The doors shall be fitted with removable-pin hinges and locking handles. Opening doors shall have stops to prevent damage to doors or hinges from overswing.
3.2
Painting
3.2.1
Indoor Equipment Where the supplier is able to provide a customised paint finish, outside surfaces of the cubicle shall be painted storm grey, colour No. N42 in accordance with AS 2700, in textured powder coat. The inside surfaces shall be painted white, colour No. N14 in accordance with AS 2700, in smooth powder coat. Cubicles that will be installed in corrosive environments shall be painted with a fit-forpurpose system rather than powder coat. Where customised painting is not available, the supplier’s standard paint system and colour may be accepted subject to approval. However, the preferred colour for inside surfaces is white, colour No. N14.
3.2.2
Outdoor Equipment Where external surfaces of outdoor equipment are to be painted, an approved paint system suitable for extended outdoor service shall be used. The paint system shall address: •
Surface preparation, including protection of threads and other vulnerable features, and treatment of difficult access parts.
•
Masking of items that must be kept paint free.
•
Timing, including time between surface preparation and the application of the first coat of paint, and the time between coats.
•
Details of each coat to be applied including the type of coating, the method of application and the required dry film thickness.
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3.3
•
The repair scheme for minor damage.
•
The applicable QA provisions.
Cable Entry Floor mounted equipment shall be configured to accommodate cabling from both above and below. Cable entries shall be designed for glanding of all control cables. Sufficient space in gland plates etc. shall be provided for the installation of at least two additional control cables in the future, and to accommodate cables with at least 15% spare cores.
3.4
Access All controls, alarms, and indications shall be mounted for ready Operator access at the front of the cubicle. Access to equipment, terminal strips and wiring for maintenance shall be unimpeded.
3.5
Lifting Points Where appropriate, equipment shall be provided with lifting points suitable for slinging the equipment complete with all components installed.
3.6
Fixing Points Fixing and mounting holes shall be welded or drilled and painted in the supplier’s works at locations to be shown on the general arrangement drawings. All fixing and mounting holes shall be positioned to allow comfortable use of the appropriate tool during installation at site.
3.7
Colour Convention for Controls and Indications
3.7.1
1500V and High Voltage Devices A red indication shall indicate that the switch is closed. A green indication shall indicate that the switch is open. A red control shall cause the switch to close.
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A green control shall cause the switch to open. Note:
This colour requirement is the opposite of the convention as defined in Table 7.1 of AS 2067.
Push Buttons Action:
)
Mechanical Indicator
CLOSE OPEN
O CLOSEDD
= Circuit Breaker Open = Circuit Breaker Closed
Figure 1 3.7.2
Low Voltage Devices A red indication shall indicate that the switch is closed. A green indication shall indicate that the switch is open. A green control shall cause the switch to close. A red control shall cause the switch to open.
3.8
Equipment Mounting All control equipment and circuitry shall be mounted so that it is easily removable for maintenance. This may be achieved by the use of plug-in modules or an equivalent method.
3.9
Labelling
3.9.1
Language All labelling shall be in the English language only.
3.9.2
Equipment Labels All individual components and items of equipment shall be labelled by “Traffolyte” or similar material which shall remain legible over the life of the equipment when subjected to all reasonable mechanical wear and abrasion conditions. Lettering shall be black letters on white background.
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Labels shall be mounted on a fixed portion of the cubicle or compartment and not on the actual components, equipment or duct covers. Labels shall be positioned to remain visible after wiring and cabling are completed and so that components and equipment are not blocked from view. Components and equipment mounted inside the cubicle or compartment shall be labelled with the schematic designation (eg “52OP”) in lettering of not less than 3 mm in height. Operator controls and equipment on the front panel shall be labelled with the device function (eg “Open ACCB”, “DCCB Closed”) in lettering not less than 4 mm in height. Stand-alone cubicles shall also be fitted with a main label inscribed with the name (eg “No. 1 Rectifier Control Cubicle”) in lettering of not less than 15 mm in height. Specific labelling requirements for protection equipment are detailed in EP 19 00 00 02 SP, Protection System Requirements for the High Voltage Network. 3.9.3
Terminal Strip Labels All terminals shall be clearly and indelibly labelled with the terminal number shown on the schematic diagram using proprietary labels from the terminal supplier.
3.9.4
Wire Identification & Numbering All control and protection wires shall have a unique number and shall be identified at each end by white number ferrules inscribed in black characters with the wire number shown on the schematic diagram. Ferrules shall be a proprietary, interlocking type of size to match the wire diameter.
3.9.5
Cable identification codes for schematics, cable schedule and drawings The identification codes for cables are to be used on all drawings, schedules and labeling are detailed in the table below:
ID
Category
Example application
CM COMMUNICATION
OPTICAL FIBRE, COPPER SERIAL LINKS, PILOT CABLES, TELEPHONE, DATA
C
CONTROL
CONTROL CABLES BETWEEN PANELS.
FL
FRAME LEAKAGE (RECT & DCCB)
DCCB FRAME TO FRAME LEAKAGE RELAY BAR, RECTIFIER TO RECTIFIER FRAME LEAKAGE RELAY.
E
EARTHING
EQUIPMENT EARTHS, EARTH GRID CONNECTIONS, HV CABLE SCREEN EARTHS
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IA
INSTRUMENTATION (ANALOGUE 0-20MA)
VOLTAGE & CURRENT TRANSDUCER OUTPUT CABLES, AMMETER & VOLTMETER CABLES
S
SUPERVISORY
SUPERVISORY INDICATION & CONTROL
AC
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