SP 00 E 0012 Rev 0 HV Switchgear

OWNER

KANDHKOT FIELD GAS COMPRESSION STATION (KFGCS) PROJECT Document Title:

Date: 03/09/2007

CONTRACTOR

SPECIFICATION FOR HIGH VOLTAGE SWITCHGEAR

Document No: SP-00-E-0012

Rev: 0

Class: I

Sheet 1 of 19

SPECIFICATION FOR HIGH VOLTAGE SWITCHGEAR

0

Issued for Construction

03/09/2007

ARS

SN

ShS

LiuXG

A

Issued for Approval

17/07/2007

ARS

SN

ShS

LiuXG

Rev

Description

Date

Prepared

Checked

Approved

Client

Owner

OWNER

KANDHKOT FIELD GAS COMPRESSION STATION (KFGCS) PROJECT Document Title:

Date: 03/09/2007

CONTRACTOR

SPECIFICATION FOR HIGH VOLTAGE SWITCHGEAR

Document No: SP-00-E-0012

Rev: 0

Class: I

Sheet 2 of 19

CONTENTS SPECIFICATION FOR HIGH VOLTAGE SWITCHGEAR 1 SCOPE

1 3

1.1 Introduction................................................................................................................3 1.2 Vendor Responsibilities..............................................................................................3 1.3 Scope of Supply.........................................................................................................3 1.4 Conflict of Documentation..........................................................................................4 1.5 Exceptions to Specifications / Compliance Statement................................................4 1.6 Quality System........................................................................................................... 4

2 GENERAL REQUIREMENTS

5

2.1 Codes and Standards.................................................................................................5 2.2 Data Sheets............................................................................................................... 6 2.3 Certification................................................................................................................6

3 SITE CONDITIONS

6

3.1 Environmental............................................................................................................6 3.2 Hazardous Area Classification...................................................................................6 3.3 Safety......................................................................................................................... 6

4 DESIGN AND CONSTRUCTION REQUIREMENTS

7

4.1 System Voltage and Frequency.................................................................................7 4.2 General...................................................................................................................... 7 4.3 Construction............................................................................................................... 7 4.4 Controls and DC Control Circuit Philosophy...............................................................9 4.5 Bus-Bars.................................................................................................................. 10 4.6 HV Circuit Breakers..................................................................................................10 4.7 Potential Transformers (PTs)...................................................................................11 4.8 Current Transformers (CTs).....................................................................................12 4.9 Trip Circuit Supervision............................................................................................12 4.10 Protective Relays...................................................................................................12 4.11 Instruments............................................................................................................ 13 4.12 Auxiliary Switches, Devices and Wiring..................................................................14 4.13 Terminals............................................................................................................... 15

5 ACCESSORIES

15

5.1 DC Power................................................................................................................. 16 5.2 Marking and Finishing..............................................................................................16 5.3 Inspection and Testing.............................................................................................17 5.4 Factory Acceptance Testing (FAT)...........................................................................18 5.5 Certificates of Acceptance........................................................................................19

OWNER

KANDHKOT FIELD GAS COMPRESSION STATION (KFGCS) PROJECT Document Title:

Date: 03/09/2007

1 1.1

CONTRACTOR

SPECIFICATION FOR HIGH VOLTAGE SWITCHGEAR

Document No: SP-00-E-0012

Rev: 0

Class: I

Sheet 3 of 19

SCOPE Introduction This specification covers the design, construction and supply of a High Voltage Switchgear assembly (HV Switchgear).

1.2

Vendor Responsibilities Vendor shall be responsible for the complete design, engineering, manufacture, supply, inspection, testing, documentation and preparation for shipment of the HV Switchgear, in full compliance with all applicable design Codes and Standards, including those listed in Section 2 of this document and the requirements of the certifying authority, if applicable. Purchaser’s approval of the Vendor’s drawings/documents does not in any way affect Vendor’s full responsibility to supply strictly in accordance with Project specification, codes and standards. This specification shall not relieve the Vendor of any responsibility to provide equipment and services that are suitable for the intended duty.

1.3

Scope of Supply The Vendor shall supply the following: •

Factory design, fabrication, assembly, factory acceptance testing, packaging and preparation for shipment, shipment to the site of the specified HV Switchgear

•

DC System consisting of batteries, chargers and Distribution Board for protection, control and indication circuits of the HV Switchgear

•

Design drawings and data including Single Line Diagrams, Schematics, Wiring Diagrams, Termination Diagrams, Bill of Materials, Protection Schematics and General Arrangement Drawings

•

Completed Data Sheets

•

“As Constructed” drawings

•

Installation, Operation, Maintenance and Commissioning Manuals

•

Manufacturer’s Data Report (MDR) Manual

•

Erection, testing and commissioning supervision services.

Each unit shall be a self-contained package inclusive of all equipment necessary for placing the units into immediate service.

OWNER

KANDHKOT FIELD GAS COMPRESSION STATION (KFGCS) PROJECT Document Title:

Date: 03/09/2007

CONTRACTOR

SPECIFICATION FOR HIGH VOLTAGE SWITCHGEAR

Document No: SP-00-E-0012

Rev: 0

Class: I

Sheet 4 of 19

The review and approval of any drawings, procedures or documents referred to in this Specification shall only indicate acceptance of general requirements and shall not relieve the Vendor of its obligations to comply with the requirements of the Purchase Order. Compliance by the Vendor with the provisions of this Specification does not relieve him of the responsibility of furnishing equipment of proper design, electrically and mechanically suited, to meet the operating requirements under the specified service conditions. 1.4

Conflict of Documentation In the event of a conflict between this specification and any other documentation, the Purchaser shall be made aware for clarification, before commencement of design or fabrication.

1.5

Exceptions to Specifications / Compliance Statement Deviations to the requirements of this Specification and the associated standards and documents to which the equipment shall be manufactured and tested; must be stated by Vendor in writing at the bid stage. In the absence of such a statement, it is considered that the requirements of the Specification are met without exception. Any shortcomings that are identified during or on the completion of fabrication shall be corrected by Vendor at the Vendor’s expense.

1.6

Quality System A quality control program shall be submitted to the Purchaser for review and approval prior to commencement of the work. The quality program shall include all Subcontractors. The Vendor shall maintain an effective program for quality assurance and quality control, planned and developed in conjunction with all manufacturing, storage and application functions necessary to meet the requirements of the Purchase Order and this Specification. The Quality Plan shall ensure that quality requirements are determined prior to commencement of the work and subsequently satisfied throughout. The Supplier‘s quality system and quality control procedures shall generally conform to the requirements of ISO 9000/9001/9002; whichever is applicable.

OWNER

KANDHKOT FIELD GAS COMPRESSION STATION (KFGCS) PROJECT Document Title:

Date: 03/09/2007

2 2.1

CONTRACTOR

SPECIFICATION FOR HIGH VOLTAGE SWITCHGEAR

Document No: SP-00-E-0012

Rev: 0

Class: I

Sheet 5 of 19

GENERAL REQUIREMENTS Codes and Standards The design and installation shall comply with the following Standards and Codes of Practice: IEC 60044

Instrument Transformers

IEC 60056

High-voltage alternating-current circuit breakers

IEC 60129

Alternating current disconnectors and earthing switches

IEC 60186

Voltage transformers

IEC 60255

Electrical Relays

IEC 60265

High Voltage Switches

IEC 60282

High Voltage Fuses

IEC 60298

AC metal-enclosed switchgear and control gear for rated voltages above 1 kV and up to and including 52 kV

IEC 60332-1

Tests for electric cables under fire conditions

IEC 60420

High Voltage alternating current switch – fuse combinations

IEC 60470

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

IEC 60427

Synthetic testing of high voltage alternating current circuit breakers

IEC 60529

Degrees of protection provided by enclosures (IP Code).

IEC 60632

High Voltage Motor Starters

IEC 60694

Common Specifications Controlgear Standards

for

High-Voltage

Switchgear

and

Where the standard consists of multiple parts, the Vendor shall conform to each and every part. Where there is no applicable code or standard as mentioned above, codes or standards published by the following international organisations shall be used: •

International Electro-technical Commission (IEC)

•

Harmonised European Standards (EN)

•

British Standards Institute (BSI)

OWNER

KANDHKOT FIELD GAS COMPRESSION STATION (KFGCS) PROJECT Document Title:

Date: 03/09/2007

2.2

CONTRACTOR

SPECIFICATION FOR HIGH VOLTAGE SWITCHGEAR

Document No: SP-00-E-0012

Rev: 0

Class: I

Sheet 6 of 19

Data Sheets Purchaser’s equipment Data Sheets shall form a part of this Specification. The equipment shall comply with all the requirements of the Data Sheets DS-00-E-0017. The Vendor shall complete all information requested on the Data Sheets.

2.3

Certification The HV Switchgear shall be fully type tested by ASTA or KEMA or other recognised independent certification organization (subject to Purchaser’s approval) for adequate short circuit withstand and allowable temperature rise. The HV Switchgear shall preferably be type tested for arc fault containment. The requirement for arc fault containment shall become mandatory when called for on the Data Sheet. Vendor shall furnish details of certification with copy of the type test certificates demonstrating compliance with the latest revision of applicable standards for Purchaser’s approval.

3 3.1

SITE CONDITIONS Environmental Refer to the Specification for Environmental Design Conditions Doc No. SP-00-M-0020.

3.2

Hazardous Area Classification The HV Switchgear will be installed indoors in an unclassified (non-hazardous) location.

3.3

Safety The HV Switchgear shall conform to the following requirements: • The switchboard enclosures shall comply with IEC60298, Annexure AA with regard to mechanical strength and ability to contain an arc fault. The test condition shall be in conformity with accessibility Type A, and the switchgear shall meet assessment criteria 1 to 6 inclusive. • Switchgear and control equipment shall be designed to minimize risk due to internal short circuits and to ensure personnel safety during all operating conditions, inspections and maintenance. • To minimize fire hazards, halogen-free, flame-retardant materials shall be used where appropriate. • Toxic materials (such as asbestos, polychlorinated biphenyls (PCBs), mercury, and the like), shall not be used. • Operation of the switchgear shall be carried out with the cubicle door closed. This shall include racking in and out of the circuit breaker and contactor trucks, and application of the earth switch.

OWNER

KANDHKOT FIELD GAS COMPRESSION STATION (KFGCS) PROJECT Document Title:

Date: 03/09/2007

4

SPECIFICATION FOR HIGH VOLTAGE SWITCHGEAR

Document No: SP-00-E-0012

Rev: 0

Class: I

Sheet 7 of 19

DESIGN AND CONSTRUCTION REQUIREMENTS

4.1 4.1.1

System Voltage and Frequency System Voltage WAPDA:

4.1.2

4.1.3

11000V, 3 Phase, 3 Wire, 50 Hz

Steady state variations Steady state (long-term) voltage variation:

+5%, -10%

Steady state (long-term) frequency variation:

+/-2%

Transient state variations Transient voltage variation:

4.2

CONTRACTOR

+/-20%

General The HV Switchgear shall have bus bar configuration as shown on single line diagram. The design shall allow for the future extension of the busbar and addition of new panels at both ends of the switchgear.

4.3

Construction The switchgear shall be metal clad enclosed, free standing, dead-front, indoor type, dust and vermin-proof, standardised to form a single assembly with a common bus-bar and shall incorporate vacuum breakers/contactors. Enclosures shall have a minimum degree of protection IP41 as defined in the IEC 60529 without using the floor as part of the enclosure. The design shall allow for personnel to work safely within an empty switching device compartment, or one which has the control device assembly removed, with the bus energised. The main bus and risers shall be fully segregated and plug-in contacts for the devices shall have minimum openings. Incoming and outgoing sections shall be supplied with air insulated main power cable terminating compartments, arranged for bottom cable entry unless specified otherwise on the Data Sheets. All covers for the switchgear shall be sealed with gaskets (including back & side covers). Gaskets shall be non-deteriorating rubber or neoprene material. The switchgear shall be provided with hinged front panel doors. The compartment doors shall be attached with at least two fixings. Doors and covers of HV compartments which may be opened without the use of tools shall be provided with mechanical interlock and padlocking facilities. It shall be possible to gain safe access to breaker / control circuit

OWNER

KANDHKOT FIELD GAS COMPRESSION STATION (KFGCS) PROJECT Document Title:

Date: 03/09/2007

CONTRACTOR

SPECIFICATION FOR HIGH VOLTAGE SWITCHGEAR

Document No: SP-00-E-0012

Rev: 0

Class: I

Sheet 8 of 19

compartments while HV circuits are live. No LV components and associated LV wiring shall be located in HV compartment. The following padlocking facilities shall be provided: •

All circuit breakers and contactors in the “OFF” and “TEST” positions

•

All busbar and circuit earthing switches.

The structure shall be provided with internal barriers to prevent spreading the damage between panels when faults occur. These barriers shall also segregate power and control compartments to confine electrical disturbances and faults. The switchgear shall be factory assembled in one section or as otherwise required by shipping limitations and shall be arranged for a minimum of field assembly. The switchgear shall be suitable for future addition of units on each end. Suitable means, properly interlocked, shall be provided for earthing as follows: •

Earthing of the line side of the main incoming feeder.

•

Earthing of the load side of the outgoing feeder breakers and motor starters.

•

Earthing of bus bars.

Any of the following earthing systems is acceptable: •

A fault rated earth switch mechanically interlocked with the circuit breaker / contactor to prevent inadvertent earthing when the circuit breaker / contactor is closed.

•

An adequately rated circuit breaker able to select an earth position.

•

A suitable draw out type fault rated earthing truck replacing the circuit breaker.

All earthing switches shall be fault rated to the same fault level as the switchgear. The switchgear shall be provided with a common copper ground bus. The ground bus shall extend through the entire length of the composite switchgear and shall be provided with facilities for connection to Purchaser’s copper earth system. All equipment shall be interlocked to ensure safe operation. Warning notices shall be mounted on all devices that may be damaged or cause harm to personnel or equipment if operated incorrectly. The switchgear shall be mechanically and electrically interlocked to prevent: •

Removal of the circuit breaker from its normal operating position when the breaker is in its closed position.

•

Switching of earth switch when circuit breaker is in service operation.

OWNER

KANDHKOT FIELD GAS COMPRESSION STATION (KFGCS) PROJECT Document Title:

Date: 03/09/2007

CONTRACTOR

SPECIFICATION FOR HIGH VOLTAGE SWITCHGEAR

Document No: SP-00-E-0012

Rev: 0

Class: I

Sheet 9 of 19

•

Disconnecting of Low Voltage (LV) or auxiliary system when circuit breaker is in operation.

•

Switching ON circuit breaker when earth switch is in closed position.

•

Insertion of the circuit breaker into its normal position when the earthing switch is in its closed position.

•

Closing of the earth switch when in service position.

•

Closing of the circuit breaker, unless the primary disconnecting devices are in full contact, or separated by a safe distance.

Grounded metal safety shutters shall be provided to automatically cover all bus bar contacts and insulating spouts or isolating contacts whenever circuit breakers are withdrawn. The opening and closing of the shutters shall be by positive mechanical means whilst racking-in or out the circuit breaker or contactor. All sections shall be designed and arranged for lifting from the top, which may utilise removable lifting brackets. Provisions shall be made for lifting the switchgear assembly and bolting it into position. All items of equipment shall be arranged in a logical manner to facilitate ease of operation, maintenance and repair. All metallic non-current carrying parts, not inherently bonded together, shall be bonded together and connected to the earth bus. Arc containment barriers shall be provided by means of internally enclosed chambers. Hinged and draw out type compartment doors shall be effectively earthed through a flexible connection or a wiping contact. Proper clamps and supports shall be provided inside the cable and connection cubicle for fixing and supporting incoming and outgoing cables with suitable clearances. 4.4

Controls and DC Control Circuit Philosophy Vendor shall supply DC System and DC Distribution Board as part of HV Switchgear. a) The “close” and “trip” circuits of the HV circuit breakers and contactors shall be supplied from DC distribution board supplied with the switchgear. DC control circuits for all incomers and outgoing feeders shall be supplied directly from the distribution board (one DC circuit per feeder). Each panel shall have separate “trip” and “close” circuits. Each circuit shall be protected separately by MCB (all MCBs shall be equipped with auxiliary contacts wired to the terminal strip). b) It shall be possible to isolate either the “trip” or “close” circuit in any panel, without affecting any subsequent panels. The sub-circuit for the DC spring charging motor shall be fuse protected. Protection shall be coordinated with the closing circuit MCB.

OWNER

KANDHKOT FIELD GAS COMPRESSION STATION (KFGCS) PROJECT Document Title:

Date: 03/09/2007

CONTRACTOR

SPECIFICATION FOR HIGH VOLTAGE SWITCHGEAR

Document No: SP-00-E-0012

Rev: 0

Class: I

Sheet 10 of 19

c) Vendor shall size and supply DC battery charger, batteries, battery rack and DC distribution board. The battery bank shall be sized to support the switchboard DC System for a duration stated in Section 5.1. Vendor shall provide clamps and supports inside the cable connection cubicle for fixing and supporting incoming and outgoing cables with suitable clearances. 4.5

Bus-Bars The bus-bars shall be hard-drawn high conductivity copper with high-pressure bolted type connections. The busbar system (main and droppers) shall be fully insulated throughout. The busbar insulation shall be continued into the main switching device compartment as far as practicable. Insulation material shall be epoxy coating type material, flame-retardant, non-hygroscopic and non-tracking type. Tapered bus-bars shall not be acceptable. Factory supplied HV rated insulating tape shall be utilised for busbar joints on site. All bus-bars, including plug-in stubs and insulation, shall withstand thermal and magnetic effects of the specified short-circuit current imposed on the electrical system for the period stated in the Data Sheets. The main earth bus-bar shall be sized to withstand the thermal and dynamic stresses of a bolted earth fault equal to the switchgear rating for the period stated in the Data Sheets. Where allowance for thermal expansion is required, bus-bars shall be joined by double bolted connections with flexible joints. Bus-bar ends shall be drilled and finished for future extensions at both ends. The bus-bars and taps of feeder circuits shall be rated to carry the maximum rating of the circuit breaker. Bus-bar droppers shall have the same cross section for their full length. The sequence of the busbars shall be red-white-blue, top to bottom, left to right and back to front, all relative to the front of the switchboard.

4.6

HV Circuit Breakers The circuit breakers shall be motor operated spring charged vacuum circuit breakers (as specified on the Data Sheet) withdrawout type construction. Circuit breakers shall be suitable for uninterrupted duty, short circuit breaking capacity (including DC component) and withstand over-voltage transients when interrupting running currents of small motors or the magnetising current of the transformers.

OWNER

KANDHKOT FIELD GAS COMPRESSION STATION (KFGCS) PROJECT Document Title:

Date: 03/09/2007

CONTRACTOR

SPECIFICATION FOR HIGH VOLTAGE SWITCHGEAR

Document No: SP-00-E-0012

Rev: 0

Class: I

Sheet 11 of 19

All HV circuit breakers shall be fully removable without the need for handling trucks or the manual disconnection of wire plugs or sockets. Direct driven mechanical indication of the switching device position shall be visible from the switchgear front. Indication Light Emitting Diodes (LEDs) shall also be provided. Control supply voltage of the circuit breaker shall be DC Voltage mentioned in the Data Sheet. Each circuit breaker shall be mechanically and electrically trip-free and have a provision for manual closing and tripping. All circuit breakers of identical current rating shall be interchangeable. Circuit breakers shall have surge arrestors on the outgoing feeders, only if recommended by the Vendor. Mechanical counters shall be provided for all circuit breakers. The circuit breakers shall include all necessary auxiliary switch contacts and shall have the following contacts, wired to accessible terminal blocks for Purchaser's use: •

Minimum four (4) normally open contacts

•

Minimum four (4) normally closed contacts

The circuit breakers shall have an anti-pumping feature and manually reset lockout relays to prevent circuit breaker re-closing when tripped by protective devices. Mechanical indications shall be provided on the circuit breakers to indicate operating position of the breaker. 4.7

Potential Transformers (PTs) Potential transformers shall be of epoxy resin or butyl rubber moulded type and shall have the same insulation level as the switchgear. The accuracy shall be Class 1 for metering PTs as per IEC 60186 or as per equivalent AS. The accuracy class for protection PTs shall be 3P as per IEC 60186 or as per equivalent AS. Vendor shall provide PTs with better accuracy class where required for specific applications. Each potential transformer shall be protected with current limiting primary and secondary fuses. Each set of potential transformers, and its protective fuses shall be assembled in a separate compartment, and so arranged that the unit can be readily withdrawn from the operating position. In the withdrawn position, the potential transformer and fuses shall be completely disconnected from service and all exposed parts visibly grounded. All live parts shall be inaccessible to personnel, or so interlocked that these shall be accessible only in the de-energised condition.

OWNER

KANDHKOT FIELD GAS COMPRESSION STATION (KFGCS) PROJECT Document Title:

Date: 03/09/2007

4.8 4.8.1

CONTRACTOR

SPECIFICATION FOR HIGH VOLTAGE SWITCHGEAR

Document No: SP-00-E-0012

Rev: 0

Class: I

Sheet 12 of 19

Current Transformers (CTs) General Insulation of current transformers shall be of epoxy resin or butyl rubber moulded type and shall have the same insulation level as the switchgear. The transformers shall comply with the requirements stated in IEC 60044 or equivalent AS. The accuracy class shall be Class 1 for metering CTs as per IEC 60044 or equivalent AS. The accuracy class for protection CTs shall be 5P20 as per IEC 60044 or equivalent AS. Vendor shall provide CTs with better accuracy class where required for specific applications The current transformers shall be suitable for withstanding the stresses corresponding to the thermal and dynamic short-circuit currents imposed on the electrical system for the time rating of the Switchgear. All current transformers shall have rating as shown on the single line diagram. The Vendor shall state the ratio, burden and accuracy class of all CTs. CT secondaries shall be provided with shorting links facility. Current transformers used for unit protection system, shall be similar in characteristics at both ends of the system, and shall be selected in accordance with the relay manufacturer's recommendations.

4.8.2

CTs for Differential Protection Vendor shall mount one set of the CTs in the HV switchgear and shall supply the second set loose for installation on the protected equipment (e.g. generator, motor, transformer). Purchaser will supply information regarding the mounting details, diameter of the CTs etc. for the equipment end, required by the Vendor, after placement of the order.

4.9

Trip Circuit Supervision Trip circuit supervision relays along with indicating LEDs shall be provided for all circuit breakers and contactor starters/feeders.

4.10 Protective Relays 4.10.1 General The HV switching devices shall be equipped with the type of protection indicated on the single-line diagram. Protective relays shall be flush mounted draw-out type preferably with built-in test facilities. Any protective relays without built-in test facilities shall be provided with separate test terminal blocks mounted on the front panel of the switchgear.

OWNER

KANDHKOT FIELD GAS COMPRESSION STATION (KFGCS) PROJECT Document Title:

Date: 03/09/2007

CONTRACTOR

SPECIFICATION FOR HIGH VOLTAGE SWITCHGEAR

Document No: SP-00-E-0012

Rev: 0

Class: I

Sheet 13 of 19

Each protective relay shall be fitted with a flag indicator, which can be reset externally. Under-voltage relays shall be fed from potential transformer located in the bus section and shall be wired to the trip circuit of the motor starters. The under-voltage circuit shall not be connected to lockout relays. All incomers and feeders shall be provided with micro processor based protection relays. 4.10.2 Protective Relay Co-ordination If specified, vendor shall provide recommended settings for each of the relay being supplied as part of HV Switchgear, based on the following information to be supplied to Vendor after placement of order: (i)

Maximum and minimum fault level

(ii)

Information on Transformer

(iii)

Information on time current characteristics of downstream LV Switchgear/MCC protections.

Vendor shall request all relevant system information and information for downstream LV system required by Vendor for protective relay co-ordination. Vendor shall provide complete calculations and graphs showing time current characteristics of relays for recommended settings to show how co-ordination has been achieved. The co-ordination gaps shall be clearly visible on all graphs. 4.10.3 Relay Programming Vendor shall supply all relays pre-programmed (for required outputs, inputs, logic etc) and set to work in accordance with the settings calculated. Vendor shall test protection settings at Vendor’s works. In addition Vendor shall supply the required software for down loading of all required settings to all relays. Prior to commencement of construction Vendor shall submit details of the relay programming together with detailed drawings of the switchgear for approval by Purchaser. 4.11 Instruments The instruments shall be flush mounted, taut band switchboard type, and wide angle with a scale deflection not less than 240° back connected and with an accuracy of 1.5% of Full Scale Deflection. An external “zero” adjustment shall be provided. Watt-hour meters shall have cyclometric registers and shall normally be of 2-element type. The requirements for instruments shall be as shown on the single-line diagrams.

OWNER

KANDHKOT FIELD GAS COMPRESSION STATION (KFGCS) PROJECT Document Title:

Date: 03/09/2007

CONTRACTOR

SPECIFICATION FOR HIGH VOLTAGE SWITCHGEAR

Document No: SP-00-E-0012

Rev: 0

Class: I

Sheet 14 of 19

Ammeter scales shall indicate full-load current at approximately 60% of full scale. 4.12 Auxiliary Switches, Devices and Wiring Internal wiring (excluding main HV power circuits) shall be moisture resistant PVC, 600V grade, flexible, tinned copper stranded type conductor (minimum 30 strands is required). The wiring shall be flame retardant to IEC 60332-1. Conductor ends shall be fitted with a crimped termination device with an insulated shank. When more than two conductors need to be connected together, terminals which utilise permanent solid links, shall be provided. Terminals for different AC voltages shall be separated from each other using barriers and completely segregated from DC circuits. All terminals on door mounted equipment / devices that normally remain energised when the circuit breaker is withdrawn shall be fully shrouded. Terminals for connection of 240V AC and above shall also be shrouded. Wiring terminal blocks shall be arranged and positioned to afford easy access for cabling, testing, inspection and maintenance. For current and voltage transformer secondary circuits, terminals with facilities for measuring, isolating or short circuiting as necessary shall be provided. Each switchgear cubicle shall be equipped with an anti-condensation heater, a manual control switch and a pilot LED with identifiable indication. All internal heaters and thermostats shall be completely internally wired A separate DC control power bus, complete with terminals for an incoming feeder, shall be furnished for each bus section. Each panel shall be equipped with the following indication LEDs: •

Circuit breaker closed:

Red

•

Circuit breaker open:

Green

•

Trip circuit healthy:

White

•

Fault trip:

Amber

•

DC Failure:

Blue

Separate circuit breakers (MCBs) shall be provided for control power for each unit. Tripping of control circuit MCB shall be annunciated as a fault. Fuses and/or MCBs shall be used for protecting voltage circuits of metering supplies and auxiliary equipment e.g. space heaters. The minimum size of control wiring shall be 1.5mm² except for CT secondaries, which shall have 2.5mm² wiring.

OWNER

KANDHKOT FIELD GAS COMPRESSION STATION (KFGCS) PROJECT Document Title:

Date: 03/09/2007

CONTRACTOR

SPECIFICATION FOR HIGH VOLTAGE SWITCHGEAR

Document No: SP-00-E-0012

Rev: 0

Class: I

Sheet 15 of 19

Internal wiring shall be run in ducts to facilitate safe insertion and removal of individual wires. The inter-panel wiring shall be terminated on terminal blocks at shipping breaks. Local trip buttons located on switchgear shall operate independent of remote trip buttons. All internal wiring shall be ferruled with the respective wire number, clearly and durably marked in black on the white background. 4.13 Terminals The switchgear shall be equipped with a set of relays for remote annunciation of faults. The switchgear shall be supplied complete with an air insulated main power cableterminating compartment. Removable un-drilled brass gland plates of a minimum thickness of 5mm shall be provided for both power and control cables. Terminal blocks shall be placed at least 200mm away from gland plates. Klippon or similar terminal blocks shall be supplied for outgoing control cable terminations. The outgoing cable terminal blocks shall have the Vendor's standard wire numbering on the equipment side of the terminal block and the incoming cable and core numbers on the outgoing side of the block. Shrouded terminals shall be provided for 240V and above AC connections. Terminals of different voltages shall be segregated. Terminals for power cable shall be sized for the cable specified on the Data Sheets and single-line diagrams. All other terminals shall be sized for 2 x 2.5mm². Vendor shall furnish all terminals including 20% extra terminals as spare. 5

ACCESSORIES The switchgear shall include the following accessories as a minimum: •

Lifting lugs

•

Touch-up paint

•

Standard accessories and special tools.

A complete set of standard accessories for the switchgear, including test jumpers, test rack and a set of special tools necessary for the erection, commissioning, maintenance, and operation shall be provided. They shall be contained in a suitable box or container with locking facility.

OWNER

KANDHKOT FIELD GAS COMPRESSION STATION (KFGCS) PROJECT Document Title:

Date: 03/09/2007

5.1

CONTRACTOR

SPECIFICATION FOR HIGH VOLTAGE SWITCHGEAR

Document No: SP-00-E-0012

Rev: 0

Class: I

Sheet 16 of 19

DC Power The DC Power System shall be 24V DC unless stated otherwise on the Data Sheets. The DC power supply system shall consist of: 

One (1) battery charger



One (1) battery bank



One (1) DC distribution board.

Battery charger shall be capable of supplying the maximum load that can occur on the DC system (e.g. spring charging of circuit breakers and contactors after tripping of all of them, maximum simultaneous tripping load and additional 20% spare capacity) in addition to the boost (equalising) charging of the battery bank. Battery charger shall be equipped with set of contacts for remote alarm “charger failure”. Recharged battery shall maintain the system during mains power supply failure for a minimum duration of 1 hours at maximum loading of controls and indications. Battery shall be sized to adequately satisfy switchgear requirements with 20% spare capacity. The module-isolating switch for battery and battery charger shall be a miniature circuit breaker. The front panel of battery charger shall be fitted with two indicator LEDs and an analogue meter scaled to read DC output volts. One LED shall indicate primary circuit healthy and the second LED shall indicate battery charger failure. 5.2 5.2.1

Marking and Finishing Nameplates / Labels Machine engraved nameplates/labels with full text shall be installed to designate the purpose of all circuits, instruments, meters, relays and fuses. Circuit identification nameplates/labels shall be labels on the back as well as on the front of each compartment. All nameplates / labels shall be adjacent to the devices and not mounted directly on the devices. All labels shall be of non-corrodible type, engraved or printed in English, and shall be of sufficient size to provide easy reading from normal operating and maintenance positions. Nameplates/labels shall be manufactured from laminated plastic, showing black lettering on a white background. Each cubicle on the switchgear shall have labels on doors, switches, shutters, or where necessary to caution, warn, or indicate safety precautions, and any other information deemed necessary for personnel protection.

OWNER

KANDHKOT FIELD GAS COMPRESSION STATION (KFGCS) PROJECT Document Title:

Date: 03/09/2007

CONTRACTOR

SPECIFICATION FOR HIGH VOLTAGE SWITCHGEAR

Document No: SP-00-E-0012

Rev: 0

Class: I

Sheet 17 of 19

Nameplates shall be securely mounted with machine screws such that they may be easily changed or replaced. Labels shall be securely fixed to the equipment using not less than two fastenings bolts. Nuts and washes shall be zinc or cadmium plated. Fastenings shall not loosen due to vibration. The main switchboard labels with switchboard details shall be mounted using bolts nuts and washers as per specification. All other labels such as for individual drives etc. shall be mounted using adhesives. Warning and danger labels shall have red lettering on a white background. 5.2.2

Finish All metal parts shall be protected from rust and corrosion by plating or painting. Painted parts shall be to Vendor standard painting procedure. Vendor shall submit painting specifications and procedure to the purchaser for approval. All other parts, such as handles, levers, and fasteners that are not stainless steel shall be cadmium, nickel or chrome-plated. A minimum of 300 ml can of matching touch-up paint shall be furnished with each three(3) vertical sections of switchboard cubicle line-up or fraction thereof. The fully assembled panels shall be mould and vermin-proof and shall be treated to provide a lasting durability under the specified service conditions.

5.2.3

Site Storage A set of recommendations, based on the project environmental conditions and detailing measures to preserve the quality/integrity of the switchgear during a 12 months ‘site storage in the open’, shall be provided by the Vendor.

5.2.4

Erection and Special Tools Special tools and equipment, including circuit-breaker-handling trolley's if they are required, for erection, commissioning, maintenance and testing shall form part of the order and be shipped together with the assembly.

5.3

Inspection and Testing The switchgear shall be fully assembled, wired and tested at the factory and subjected to rigorous QA and testing at all stages of manufacture. The tests shall be carried out by the Vendor at his works, in accordance with relevant Standards in Section 2 and the requirements of this specification, unless agreed otherwise.

OWNER

KANDHKOT FIELD GAS COMPRESSION STATION (KFGCS) PROJECT Document Title:

Date: 03/09/2007

CONTRACTOR

SPECIFICATION FOR HIGH VOLTAGE SWITCHGEAR

Document No: SP-00-E-0012

Rev: 0

Class: I

Sheet 18 of 19

All formal testing will be conducted in accordance with a written test procedure. The Vendor’s test procedures shall be submitted to the Purchaser prior to the factory acceptance test for approval. Each formal acceptance test must be signed by the Vendor’s and the Purchaser’s representatives at the successful completion of the test. The Vendor shall ensure that adequate notice (a minimum of 15 working days) is given in writing to the Purchaser prior to the factory acceptance testing. The Vendor shall afford full facilities to the Inspector during the course of manufacture and shall arrange access to any Sub-vendor’s works where necessary. Details of this requirement shall be resolved in pre-inspection meetings. The acceptance of the work by the Inspector and its release for shipment shall in no way relieve the Vendor from any responsibility for carrying out all of the provisions of this specification and relevant documentation, nor does the Purchaser, by such approval and release, assume any responsibility for such provisions. All test and inspection data shall be legible, including the name and signature of the Vendor and, where applicable, the Inspector. All defects in materials detected during testing shall be repaired or replaced by the Vendor at no cost to the Purchaser. If the correction of any error or defect involves serious alterations requiring replacement of parts, the approval of the Purchaser shall be obtained before proceeding. If the correction of the error requires witnessing by the Inspector, the Inspector shall sign the correction. Retesting of repaired or replaced materials shall be mandatory. If any part of the equipment is damaged after tests have been completed, retesting of the affected parts is mandatory. The method of repair shall be in accordance with the Vendor’s standard procedures and approval of the Purchaser. The Vendor shall supply supervision, specialist personnel and all necessary materials to support the inspection and testing. All test equipment shall be in good working condition and shall have been calibrated by an endorsed laboratory. Copies of calibration certificates shall be provided to the purchaser prior to the commencement of testing. Testing shall be carried out by the Vendor and will be witnessed by the Purchaser or his nominated Inspector at various stages of manufacture and assembly. 5.4

Factory Acceptance Testing (FAT) The FAT shall be conducted in accordance with the Vendor’s standard QA procedures. The Vendor’s standard procedures shall be submitted to the purchaser at least two (2) months prior to testing for approval.

OWNER

KANDHKOT FIELD GAS COMPRESSION STATION (KFGCS) PROJECT Document Title:

Date: 03/09/2007

CONTRACTOR

SPECIFICATION FOR HIGH VOLTAGE SWITCHGEAR

Document No: SP-00-E-0012

Rev: 0

Class: I

Sheet 19 of 19

The Vendor shall be responsible for generating the FAT procedures. A 100% correct performance is required. The scope and manner of routine testing shall be in accordance with IEC 60298. The FAT shall include as a minimum the following: •

Visual inspection to prove conformity with the approved drawings and the order.

•

Spot checks to verify the degree of protection; reliability of operating mechanisms, interlocks and safety features; insulation levels; creepage distances; earthing; labelling and interchangeability.

•

Main and auxiliary cable circuits checked against approved schematic circuit diagrams.

•

Insulation resistance tests.

•

Ductor testing of all bus-bar connections.

•

Dielectric tests on all main, control and auxiliary circuits.

•

Primary and secondary injection tests.

•

Phase sequence and polarity tests

•

Full functional testing of circuits for correct mechanical and electrical operation, including the operation of their control, communications, interlocking, alarming and protective devices.

Following the above tests, the switchgear and their components shall be examined for any damage and to ensure that all parts are in satisfactory operating condition. Complete records of the above inspection and tests shall be compiled into one inspection document by the Vendor. On completion of the FAT the switchgear shall be checked and shipped to the nominated destination. 5.5

Certificates of Acceptance On satisfactory completion of the FAT, the Vendor shall provide an appropriate certificate of equipment acceptance. Attached to these certificates shall be all test records and other relevant documentation. These shall form part of the Manufacturer’s Data Report (MDR). The Purchaser will review and approve these certificates. Final acceptance of the Switchgear/MCC shall be on satisfactory completion of the Warranty period.