Type298. User Guide for Circuit Breaker Cubicle. Switchgear & Instrumentation. Medium Voltage IEC Switchgear and Motor Control Centres

Transcription

1 Switchgear & Instrumentation Type298 Medium Voltage IEC Switchgear and Motor Control Centres User Guide for Circuit Breaker Cubicle Incorporating PowlVac 100 TM Circuit Breaker Issue Date: January 2014 Document Revision 2.3 Doc Ref: STD-CUS-030

2 REVISION HISTORY Revision Date Description Prepared /12/11 Original created from several existing IOMs and Technical Charlotte Pestell Data sheets /12/11 Updated to incorporate comments from collaborative crossdepartment Charlotte Pestell review meeting /01/12 Updated to include required branding modifications Charlotte Pestell /01/12 Updated to incorporate comments following review Charlotte Pestell 2.2 2/1/13 Updated to reference STD/CUS/020 for lifting procedures Paul Dale /01/14 Updated Sect. 6.6./Added Sect 6.4 for 95kV BIL specific requirements/ Updated Sect for Vib & Seismic Installation requirements. Ignitius Milomo The Design and Development Department is responsible for the data contained in this standard document. The relevant departmental managers and team leaders are responsible for ensuring the correct use of this data within their departments. The Engineering Manager is responsible for the correct use of the data within the Contract Engineering department. AUTHORISED BY SD&D Manager DATE _28 nd January 2014 P Dale

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4 Contents 1 Getting Started About this User Guide How to Use this User Guide Application Notes Introduction Overview Equipment Specifications Mechanical Specifications Enclosure Special Climatic Operating Conditions Weights and Dimensions Electrical Specifications Switchboard Specifications Continuous Current Ratings Internal Arc Classification Circuit Breaker Cubicle Construction Withdrawable Circuit Breaker Compartment Low Voltage Control Compartment VT Compartment Busbar Chamber Cable Chamber CT Specifications Cable Terminations Dispatch and Storage Condition on Delivery Packing Export Packing Transport Delivery and Intermediate Storage Installation Overview Switchroom Requirements Mounting Foundation Frame or Unistrut Switchroom Floor Raised Plinth Installation requirements specific to Vibration and Seismic switchboard Requirements specific to 95kV Basic Impulse Level (BIL) Switchboard Busbar Chamber wide PV100 VCB Requirements wide PV 100 VCB Requirement Tier Requirements...22 TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3 Page 4 of 53

5 6.5 Mechanical Assembly Site Requirements Assembly of Cubicles Cubicle Fixing Bolts Assembly of Busbars Assembly of Arc Ventilation Plenum Torque Settings Electrical Connections Connection of Mains Power and Control Cables Earthing the Switchboard Final Installation Extension Cubicles Pre-Commissioning Overview Pre-connection Checks General and Visual Checks Control Wiring Completion Checks Low Ohm (Ducter) Tests (Minimum 50A) Primary Injection Tests Secondary Injection Tests Power Frequency Pressure (Flash) Tests Insulation Resistance Tests (Minimum 5kV) Electro-Mechanical and Functional Checks Protection Relays Final Checks Energisation Standard Tools Special Tools Loose Items Lubricants and Cleaning Agents Operation of the VCB Cubicle Insertion and Withdrawal of the Circuit Breaker Insertion Withdrawal Test/Isolated Position Interlocks General Interlocks Key Interlocks Operating Mechanism Earthing Switch Shutters Maintenance Cradle Voltage Transformer Insertion Withdrawal Busbar Earthing Truck Insertion Withdrawal Operation...46 TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3 Page 5 of 53

6 9 Maintenance Overview Inspection and Servicing Inspection Servicing Repairs Cubicles Replacement of VT Primary Fuses Electro-Mechanical Interlock Checks Circuit Breaker Circuit Earthing Switch...50 Appendix 1: Abbreviations/Glossary of Terms...51 Appendix 2: Related Documents...52 List of Figures Figure 1 VCB Cubicle Layout 9 Figure 2 Busbar Barrier 19 Figure 3 Busbar Joint end Seals 19 Figure 4 Additional CT Support 20 Figure 5 V-Rubber Fitted to Busbar Chamber Cut-out 20 Figure 6 Shrink-wrapped contact Arms 20 Figure 7 Screw Caps on all Contact Mounting Bolts 21 Figure 8 Screw Caps on all Contact Mounting Bolts 21 Figure 9 Standard Inserts replaced by GP03 Blocks 22 Figure mm Wide Tier Shutters 22 Figure mm Wide Shutters 23 Figure 12 Locating of Riser and Busbar Joint Plates into cover slots prior to strapping 25 Figure 13 Busbar Arrangement for Middle Tier (Side View) 26 Figure 14 Busbar Arrangement for End Tier (Plan View) 27 Figure 15 Earth Screen Connection 31 Figure 16 Circuit Breaker Operation 37 Figure 17 Interlock Box 39 Figure 18 Earthing Switch Operation 41 Figure 19 Shutters 42 Figure 20 Shutter Operating Mechanism 42 Figure 21 Maintenance Cradle 43 Figure 22 Voltage Transformer 44 List of Tables Table 1 Mechanical Enclosure Specifications Table 2 Standard Cubicle Dimensions (mm) Table 3 Standard Weights of Loose Mechanical Items (kg) Table 4 Switchboard Electrical Specifications Table 5 Continuous Current Ratings (A) Table 6 CT Class Table 7 Mounting requirements for Vibration and Seismic Switchboard TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3 Page 6 of 53

7 1 Getting Started IMPORTANT NOTICE READ THIS FIRST This User Guide does not purport to cover every detail of the installation and operation of the switchgear. Requests for further guidance or information on this or any other product should be directed to Powell UK. Our switchgear is manufactured in accordance with IEC standards. Powell UK cannot provide any assurances that this product will comply with the wide variety of local codes, regulations or ordinances that apply in different areas of the world. 1.1 About this User Guide This user guide provides user operation, installation and maintenance instructions for the TYPE 298 Switchgear. The purpose of this user guide is to familiarize the user and maintenance personnel with the basic capabilities of the switchgear. Only proven safe installation techniques are covered in this user guide. This user guide was not prepared for inexperienced maintenance personnel. It is not intended to constitute a training program or to provide sufficient background for personnel, not experienced with this type of electrical system, to install the system described in this user guide. The end user is responsible for ensuring that no persons should be authorised to install or carry out maintenance work on the system without having read this user guide. All rights reserved. Re-production of any part of this user guide in any form whatsoever without the written permission of Powell UK is forbidden. Additional copies can be obtained from the After Sales Services Dept. of Powell UK, Bradford, United Kingdom. The information contained within this user guide is confidential and cannot be transferred to a third party without the written consent of Powell UK. All efforts have been made to ensure the accuracy of the contents of this user guide. However should any errors be detected, Powell UK would greatly appreciate being informed of them. The above notwithstanding Powell UK can assume no responsibility for any errors in this user guide or the consequences thereof. The policy of Powell UK is one of progressive improvement in design, construction and operation. Systems and equipment referred to in this user guide are subject to changes in keeping with this policy. The manufacturer, therefore, reserves the right to make any changes without prior notice. 1.2 How to Use this User Guide This user guide is arranged and subdivided to provide useful information with a minimum of searching. The key to easy reference is the Table of Contents. Every subject, in the Table of Contents, is listed with a reference number and the page on which the item can be found. Each subject is numbered by Chapter, Paragraph and Sub-paragraph, for example: " - Chapter number. 1" - Main paragraph topic. 2" - Breakdown of Main paragraph topic. The page number, along with the number of pages in this user guide, is located in the outside corner of each page. For convenience, all illustrations and tables are numbered in sequential order. TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3 Page 7 of 53

8 Familiarity with the Table of Contents will facilitate locating particular information easily. Personnel responsible for the system should review all of the Table of Contents for future reference and an overall understanding of the user guide. Then read the user guide and study the illustrations thoroughly. 1.3 Application Notes MV Switchgear Warranty Powell UK warrant the switchgear against defects in material or workmanship under normal use for a period of 18 months from the date of shipment from our premises or 12 months from the date the equipment is put into service, whichever occurs first. In the event of a failure arising during the warranty, Powell UK will undertake to repair or replace the switchgear at our option, provided always that it is found to be defective. The warranty obligations of Powell UK will not extend to defects caused by wrong or negligent operation, accident, overloading, unsuitable operating conditions, or by failure of the End User to comply with any instruction given by Powell UK with regard to its operation or installation. Powell UK is not liable under any circumstances for special, economic, financial, indirect or consequential damages (including loss of profit, loss of use, loss of production, loss of contracts) or for expenses sustained as a result of switchgear malfunction or incorrect application. Safety at Work. The voltages present in certain parts of the switchgear are capable of inflicting a severe electric shock and may be lethal. It is the responsibility of the owner and / or the End User to ensure that the installation of the switchgear and the way in which it is operated and maintained complies with the requirements of the Health and Safety at Work Act in the United Kingdom, and with other applicable legislation and regulations and codes of practice in the UK or elsewhere. The manufacturer accepts no liability for any consequences resulting from inappropriate or incorrect installation of the equipment. Training If additional training is required then contact Powell UK or their designated agent. Type of operating environment The intended operating environment is limited to being housed within an electrical switchroom or substation that is suitable for protecting the equipment. Access to the switchroom and switchgear must be prevented except by trained and authorised personnel. General Operating Requirements Users must have electrical experience and be able to interpret control circuit diagrams, electrical schematics and general arrangement drawings. Minimum age (years). Eighteen (18), or minimum permissible age required by End User s national law. TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3 Page 8 of 53

9 2 Introduction 2.1 Overview The Type 298 MV (Medium Voltage) switchgear is a modular construction of metal enclosures incorporating various arrangements of incomer, feeder, bus tie and motor starter cubicles. The Incomer and bus tie cubicles are fitted with a Circuit Breaker (CB) and the feeder cubicles can be fitted with either a circuit breaker or a Vacuum Contactor (VC). The cubicles that make up the switchboard are connected together via a Hard Drawn High Connectivity (HDHC) copper bus bar system. HDHC copper risers are used to connect the equipment within each cubicle to the busbar system. Figure 1 VCB Cubicle Layout As can be seen from the above side view, each VCB cubicle contains: A withdrawable circuit breaker. A Low Voltage (LV) control compartment containing terminals, control relays, MCBs etc. A busbar chamber that allows the busbars to run into each cubicle for the risers to connect to. A cable chamber for incoming and outgoing connections. A voltage transformer in order to provide the control/metering supply (if required). There may not be a VT in every CB cubicle supplied, but one or two per bus/switchboard. See contract drawings for details. TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3 Page 9 of 53

10 2.2 Equipment The major components that are supplied as standard in the MV Incomer, Bus Tie and CB Feeder cubicles are as follows: Component Manufacturer Model No. Circuit Breaker Powell UK PowlVac 100 TM Earthing Switch Contact Powell UK Busbar Earthing Truck Powell UK Voltage Transformer Transmag This user guide discusses only the PowlVac 100 TM breaker. The ABB VD4 and HD4 breakers are discussed in a separate user guide. TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3 Page 10 of 53

11 3 Specifications 3.1 Mechanical Specifications Enclosure IEC Publication Description Min Max Units IEC IEC60529 High Voltage Alternating Current contactors and contactorbased motor starters Ingress Protection Rating: IP 4X (standard enclosure) IP 41 (enhanced enclosure) IP 42 (enhanced enclosure) IP 3X (between compartments) IP 2X (inside the compartments with the door open) Maximum ambient temperature C Maximum 24 hour average temperature C Storage temperature C Maximum 24 hour average storage temperature C IEC Average relative humidity over 24 hours 95 % Average value of water vapour over 24 hours 2.2 kpa Average relative humidity over 1 month 90 % Average value of water vapour over 1 month 1.8 kpa IEC IEC IEC IEC Maximum Site Altitude 1000 M High Voltage switchgear and controlgear Common specifications High Voltage switchgear and controlgear Alternating Current Circuit Breakers High Voltage switchgear and controlgear Alternating Current disconnectors and earthing switches High Voltage switchgear and controlgear AC metal-enclosed switchgear and controlgear Table 1 Mechanical Enclosure Specifications Special Climatic Operating Conditions For any operating conditions other than those described above, Powell UK must be contacted in advance. Examples of these are as follows: At site altitudes above 1000m the effects of the reduction in dielectric strength of the air on the insulation level need to be taken into account. Increased ambient temperatures must be compensated for in the design on the busbars and tee-off conductors, otherwise the current carrying capacity will be limited. Heat dissipation can be assisted by fitting additional ventilation facilities. If the switchgear is to be operated in areas with high humidity and/or major rapid temperature fluctuations, there is a risk of dew deposits. This situation can be exacerbated with low primary currents as internal heating is not achieved. Anti-condensation heaters can be fitted in order to avoid premature insulation degradation and corrosion. TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3 Page 11 of 53

12 3.1.3 Weights and Dimensions Description Current Rating Cubicle Width Cubicle Height Cubicle Depth Plenum Height Plenum Depth Overall Switchboard Height 40kA Switchboard <1600A 700mm / kA Switchboard <2000A 700mm / kA Switchboard <3150A 1000mm / kA Switchboard <4000A 1000mm Table 2 Standard Cubicle Dimensions (mm) Please note that extended depth is used when the switchboard is required to be top entry. Description 700mm 40kA Circuit Breaker 245 Cubicle Width 1000mm 1000mm (63kA) 50kA Circuit Breaker kA Circuit Breaker 415 Service Trolley TBA Shutter Operating Device Voltage Transformer Busbar Earth Truck 75 Earth Switch Operating Handle Earth Switch Extension Handle 1.5 Racking Handle Door Opening Hand Tool CB Spring Charging Handle Table 3 Standard Weights of Loose Mechanical Items (kg) TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3 Page 12 of 53

13 3.2 Electrical Specifications The specifications detailed below are based on normal operating conditions as detailed in section 3.1 Mechanical Specifications. If these conditions should differ (e.g. the site is at an altitude greater than 1000m or there is an increased ambient temperature) then Powell UK should be consulted in advance as it may have an impact on the specifications detailed below Switchboard Specifications Description Switchboard Voltage Rating (kv) Short-duration Power Frequency Withstand Voltage (kv RMS) Basic Impulse Insulation Level (BIL) Rated Frequency (Hz) 50/60 50/60 50/60 50/60 Rated Busbar Current (A) Rated Peak Withstand Current (ka) Rated Short Circuit Breaking Current (ka) Rated Short Time (3sec) Current (ka) AC Voltages: 110/220 Auxiliary voltage (V) DC Voltages: 48/110/125/220 Table Continuous Current Ratings Switchboard Electrical Specifications Fault Rating Description Available Ratings (A) (ka) 700mm wide cubicle mm wide cubicle mm wide cubicle Table 5 Continuous Current Ratings (A) Internal Arc Classification The Internal Arc Classification for the MV298 Switchgear is tested in accordance with IEC Annex A (Internal Fault Method for testing the metal-enclosed switchgear and controlgear under conditions of arcing due to an internal fault). The Internal Arc Classification (IAC) makes allowance for internal overpressure acting on covers, doors, inspection windows, ventilation openings etc. It also takes into consideration the thermal effects of the arc or its roots on the enclosure and of the ejected hot gases and glowing particles, but not damage to internal partition and shutters not being accessible in normal operating conditions. Please refer to the switchboard rating plate for specific details of the IAC of the switchboard supplied. 1 Forced Ventilation must be used for this rating. TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3 Page 13 of 53

14 4 Circuit Breaker Cubicle 4.1 Construction The Type 298 MV switchgear consists of several segregated compartments: Withdrawable Circuit Breaker Compartment Low Voltage Control Compartment VT Compartment Busbar Chamber These compartments are discussed in more detail in the following sections: The main framework and internal faces of the switchboard are manufactured from Aluzinc. Doors and covers are manufactured from mild steel and can be painted in any BS or RAL colour. 4.2 Withdrawable Circuit Breaker Compartment The circuit breaker compartment is fitted with guide rails in order to facilitate insertion and withdrawal of the breaker. This is done with the use of a Service Trolley (see section 8.1 Insertion and Withdrawal of the Circuit Breaker for further details). At the back of the compartment are earthed metal shutters that are automatically operated by the shutter operating mechanism such that no access can be gained to the primary disconnects when the breaker is in the Test/Isolated position or completely removed from the cubicle. Please refer to Section 8.6 for further details. Inside the compartment (mounted on the compartment top) is the control socket that the secondary disconnect (multi-way control wiring plug) on the breaker connects into. This connection can only be made when the breaker has been inserted into the compartment unless a special tool (CB test umbilical) is used. When the breaker has been racked from the In Service position to the Test/Isolated position it is possible to open the door and manually control the breaker using the Close/Trip buttons on the breaker itself. It is also possible to perform a manual charge using the handle supplied. The Close/Trip and Charged/Discharged indicators can be observed through the viewing window in the door when the door is closed. Anti-condensation heaters (ACH) are also fitted in this compartment as required. These are controlled via a thermostat which is located in the Low Voltage Control Compartment. Please note that at low loads, the heaters should be permanently energised. Also, where end tiers draw little or no load, these heaters should also be permanently energised. 4.3 Low Voltage Control Compartment This compartment, including the door, accommodates the auxiliary equipment of the switchgear panel. This includes any protection relays and control relays etc. LV control wiring is situated within plastic trunking and additional earthed metal trunking to the cubicle sides allows for bottom entry incoming LV connection direct to the LV compartment. Bus wiring is routed between LV compartments through the cut-outs supplied. A termination unit (TU) is also fitted into this compartment. This is used to distribute the RS485 cabling around the switchboard to any intelligent control relays that may be fitted. A thermostat is also fitted in this compartment. This is used to control the anti-condensation heaters located in the circuit breaker compartment. TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3 Page 14 of 53

15 4.4 VT Compartment This is situated below the Circuit Breaker compartment and can be equipped to accommodate a cradle mounted voltage transformer. Guide rails are fitted in order to facilitate insertion and withdrawal of the VT. At the back of the compartment is an earthed metal shutter that automatically operated by the shutter operating mechanism such that no access can be gained to the primary disconnects when the VT is withdrawn. There are no interlocks associated with the VT. The door is padlockable (a padlockable racking boss is available on request), but after that it is possible to insert and withdraw the VT irrespective of the state of the breaker. 4.5 Busbar Chamber The busbars are laid in sections from tier to tier and are held in place by post insulators mounted on the steel frame. Each busbar is constructed from 5mm HDHC copper bar insulted with an epoxy dip coating. Busbars are used in single, double, triple or quadruple configuration depending on the current rating (refer to contract documentation). The connections to the 5mm thick dropper busbars are made onto a special joint casting mounted onto the post insulator and terminated into the busbar spout mouldings. All main circuit conductors are electrotinned or silvered at the joint faces of the bolted joints which are then covered by EPDM covers. 4.6 Cable Chamber This houses the Current Transformers (CTs), mechanically operated circuit earthing switch, primary cable terminations and switchboard earth bar. Capacitive dividers and surge arrestors are also contained here if supplied. Neon indicators connected to the earth layer of the CT bushings may be fitted as an option to indicate that the circuit side connections of a cubicle are energised. Neon indicators for busbar live indication may be provided using busbar sleeving kits, or where possible, by connecting to the bushing in a bus section cubicle. Surge arrestors are fitted in this compartment where required. See contract document for details CT Specifications CTs are ring type with 600V insulation mounted onto fully fault rated CT bushings. Each bushing is constructed with an earth shield between the HV and CT windings. Alternative cast resin insulated wound primary CTs may be used in special circumstances. CTs are specified as follows: CT Class Function Max. Rating Class 1/0.5/0.2 Metering 4000A Class 5P/10P Protection 4000A Class PX Differential & Residual Earth Fault 4000A Table 6 CT Class Cable Terminations Primary cable terminations are arranged to meet contract requirements with access from above or below. Gland plates are provided at floor or unit top level with suitable accommodation for either single or multi-core cables as required by the contract. Joints can be covered with polyurethane moulded covers (boots) if required. Please refer to contract documentation for glanding details Secondary cable terminations are made either top or bottom entry. Cables are terminated in the LV Compartment. Bus wiring is routed directly between LV Compartments. Internal earth bars and inter-panel earthing is mounted in the lower section of the cable chamber. TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3 Page 15 of 53

16 5 Dispatch and Storage 5.1 Condition on Delivery The factory assembled switchgear cubicles are checked at the factory for compliance with the manufacturing order and contract documentation. All routine tests in accordance with all relevant specifications are conducted at the factory. Functional testing and interlock sequence are checked with the final inspection. Note: Horizontal busbars are not assembled within the equipment in the factory and are therefore not subjected to an AC power frequency test on the assembly (this needs to be performed following installation. Please refer to Section Power Frequency Pressure (Flash) Tests. Each busbar is however, separately tested for integrity of insulation by high voltage withstand testing. Busbars are supplied as loose material for completion at site during installation. 5.2 Packing The switchgear sections are split and packed in accordance with the contract documentation. Standard packaging consists of heavy duty welded seam polythene sheeting (minimum grade 500 gauge, micron value 125) applied to each section. Packaging is often supplied in accordance with specific customer requirements. Where the panel comprises more than one section, each piece will have an adhesive identification label. All loose materials are detailed on a dispatch note and packed in a separate carton(s). See Loose Material List supplied with the contract documentation for details. For further details, please refer to the Packing/Unpacking Specification STD/CUS/ Export Packing The switchgear sections are split and packed in accordance with contract documentation. Standard domestic packaging for export consists of a timber-framed, plywood clad case and all equipment is adequately wrapped. For further details, please refer to the Export Packing Specification STD/CUS/ Transport The switchboard sections are normally transported as individual panels, or in small groups. Each panel is fitted with two lifting channels mounted to the upper unit side frames. Please refer to contract drawings for details of the shipping splits. For recommended methods of lifting, please refer to the Lifting Procedures document STD/CUS/020. Always transport switchgear panels upright and avoid sudden shock or jolting. TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3 Page 16 of 53

17 5.5 Delivery and Intermediate Storage The responsibilities of the consignee when the switchgear arrives at the site include, but are not limited to the following: Check the consignment is complete and there is no obvious damage. In cases of doubt, the packaging may be opened and then properly resealed when intermediate storage is necessary. Precisely document any defect/transport damage and report these to the relevant authorities within two weeks. Storage is at the discretion of the consignee. Equipment packed according to customer specified documentation shall be the responsibility of the customer. Cubicles packed in our standard packing shall be stored as follows: A dry, well ventilated and preferably heated storeroom in accordance with IEC (Please refer to Table 1 Mechanical Enclosure Specifications for details of ambient conditions). Store switchgear cubicles in an upright position. Do not stack switchgear cubicles. Do not remove or damage the packaging. Loosely cover unpacked switchgear cubicles with plastic film to prevent dirt and ingress Cover all loose equipment with plastic film to prevent dirt ingress. Sufficient air circulation must be maintained to prevent corrosion. TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3 Page 17 of 53

18 6 Installation 6.1 Overview Once delivered to site, the switchgear can be assembled. This section details the switchroom requirements and the mechanical and electrical connections that must be made. We recommend that any installation work is carried out by Powell UK Site Services personnel. Please contact the Site Services team for further details regarding installation personnel and activities. 6.2 Switchroom Requirements The minimum requirement for ceiling height in the switchroom is 3000mm for a standard IEC construction switchboard. This will need to be higher for a 63kA switchboard. Please refer to Section Weights and Dimensions for further details. 6.3 Mounting It is recommended that the switchboard be mounted in one of the following ways: Foundation Frame or Unistrut The switchgear and controlgear should be erected on a foundation frame or unistrut set into the switchroom floor or onto a raised plinth. The completed foundation frame must be in accordance with: Flatness ± 1mm per 1m Straightness 1mm per 1m, but within 8mm over the entire switchboard length Please refer to contract documentation for details of the foundation layout Switchroom Floor Switchboards with few lightweight cubicles can be fitted directly to the switchroom floor if the floor is level and has sufficient load bearing capacity. If required, shims may be used to assist with alignment. The completed switchroom floor must be in accordance with: Flatness ± 1mm per 1m Straightness 1mm per 1m, but within 8mm over the entire switchboard length Please refer to contract documentation for details of the foundation layout Raised Plinth The switchboard can be supplied with a mounting plinth for mounting purposes. In order to facilitate the use of earth trucks and service trolleys, any plinth must include a withdrawal area in front of the switchboard or the switchroom floor must be screeded to the level of the plinth. Where required specific ramps can be supplied in order to provide access between different floor levels Installation requirements specific to Vibration and Seismic switchboard The bolts, washers and load spreader bars required for assembling the cubicles are defined in the table below. The bolt lengths may vary due to site specific installation requirements. Only the minimum length has been specified in the table. These items are supplied as loose items with each cubicle. Cubicles Description Qty Size Length Any cubicle to Plinth Grade 12.9 Cap Screw 1/Mounting Position M12 35mm Load Spreader 1/Screw 09092P Locking Washer 1/Screw M12 Table 7 Mounting requirements for Vibration and Seismic Switchboard TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3 Page 18 of 53

19 6.4 Requirements specific to 95kV Basic Impulse Level (BIL) Switchboard Busbar Chamber An additional GP03 plate is required. This is fitted to Busbar mounting plate (Ripple Plate) in order to act as a barrier between the Riserbar of L1 and the horizontal Busbar of L3.GP03 Brackets are provided and these must be secured using Nylon fasteners GP03 Barrier between L3 Busbar and L1 Riserbar, fitted to the Ripple Plate Figure 2 Busbar Barrier All main horizontal Busbar are coated with an insulation of between 1.6mm & 2mm thick. This reduces the gaps between adjacent bars and care must be taken when fitting the Busbar Joint End Seals which are fitted all round the boot. Replacement Busbar Joint End Seals which allow for the additional thickness of the insulation on the main Busbars are required during site installation. Their references are shown below. Figure 3 Busbar Joint end Seals Joint End Seals or Joint Plates are fitted to Riser Bars on switchboards specified for Basic Impulse Level (BIL) application. Detailed procedures for Assembly of Busbars joints are discussed in Section 6.6. TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3 Page 19 of 53

20 An additional CT support ring are placed on the CT bushings up against the original CT support Additional CT Support added Figure 4 Additional CT Support V-rubber edging strip is fitted around the cut out for the interconnecting Busbars on each tier. Ensure that these are secured. V-rubber must be fitted round the edge of the Cut-out for the Busbar Chamber wide PV100 VCB Requirements Figure 5 V-Rubber Fitted to Busbar Chamber Cut-out The contact Arms in the Pole-Moulds have been insulated on the 2000A 50kA 700mm Wide Vacuum Circuit Breaker and additional insulation shrink-wrapped and protrudes from the existing Sleeves, see image below Heat Shrink-wrapped Insulation over Contact Arm Figure 6 Shrink-wrapped contact Arms All fixing screws used for mounting contact arms onto VI s within a breaker have been replaced with button head screws and covered using relevant size caps held in place by TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3 Page 20 of 53

21 non-conductive Loctite Sealant No gaps in insulation should be visible once all caps and covers are fitted. Screw Cover Cap No visible gaps in Insulation around Nut Cap wide PV 100 VCB Requirement Figure 7 Screw Caps on all Contact Mounting Bolts Both upper and lower contact arms are insulated using powder coat insulation Button head screws are covered using relevant size caps hold in place with non-conductive Loctite Sealant Once all caps are fitted no gaps in insulation should be visible Screw Cover Cap No visible gaps in the Insulation around Nut Cap Figure 8 Screw Caps on all Contact Mounting Bolts All fixing screws used within fixing of contact arms onto the VI s have been replaced with button head screws TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3 Page 21 of 53

22 Plastic upper pole mould barrier have been replaced by GP03 barrier firmly fixed in place using non-conductive Loctite Sealant 5375 in order to ensure no gaps are present down sides or between barrier and upper contact arms Plastic Inserts have been replaced by GP03 Blocks Figure 9 Standard Inserts replaced by GP03 Blocks Tier Requirements mm Wide Tier The shutters including shutter mounting brackets are insulated. In addition, the upper shutter is fitted with a polycarbonate sheet to the rear of the insulated shutter. Nut caps are also fitted to the Shutter Mounting screws using Loctite 5375, see images below. Figure mm Wide Tier Shutters TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3 Page 22 of 53

23 mm Wide Tier The shutters including shutter mounting brackets are insulated. The upper shutter is fitted with an additional polycarbonate plate to both the front and the rear. Nut caps are also fitted to the Shutter Mounting screws using Loctite 5375, see images below. Figure mm Wide Shutters TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3 Page 23 of 53

24 6.5 Mechanical Assembly Site Requirements Prior to installation at site, the switchroom must be completely finished, provided with lighting and site electricity supply, lockable, dry and with facilities for ventilation. All the necessary preparations such as wall openings, ducts etc. for routing of the power and control cables up to the switchboard must be complete Assembly of Cubicles Ensure the cubicles are moved to the prepared installation location in the correct order. Movement can be accomplished using floor rollers (max. diameter 12mm) between the unit base plate and the site floor. It is advisable to start assembly in the middle of the switchboard for larger installations i.e. 10 cubicles and above. The assembly procedure is as follows: Refer to the General Assembly (GA) drawing for cubicle locations. Open rear doors and remove vertical partitions from the rear of the busbar chamber. Fit the neoprene gasket (supplied) to the left hand side of each cubicle (front and top). Align the cubicles onto the foundations one at a time. Ensure each section is correctly positioned relative to the neighbouring cubicle. Alignment of the front face of the switchboard is essential. Fit sections in the order shown on the GA drawing and bolt together When the switchboard has been correctly assembled, fasten the panels to the foundation fixings Cubicle Fixing Bolts Standard: The bolts required for assembling the cubicles are Grade 8.8 and the sizes and lengths are as detailed in the table below. These are supplied as loose items with each cubicle. Connecting Cubicles Description Qty Size Length Any cubicle to any cubicle Front verticals 5 M8 35mm VCB to VCB (any width) Rear verticals 10 M8 45mm VCB (any width) to VCU Rear verticals 5 M8 45mm TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3 Page 24 of 53

25 6.6 Assembly of Busbars The procedure for installing the busbars on a panel by panel basis is as follows: Clean busbars with a dry, soft cloth and check for insulation damage. Remove all grease and adhesive dirt. Slide joint covers to the base of the post insulators to provide access. Fit busbars and packers as per contract specific assembly instructions, to the joint castings and riser connections using fitting pins to provide support during assembly. Fit correct length bolts, plain and spring washers into all fixing positions, removing fitting pins to allow bolt fitting. Do not tighten. Fully fit all busbars, packers and riser connections including joint plates to the switchboard prior to tightening the fixing bolts to the specified torques. Please refer to Section 6.7 Torque Settings for details. When all joint bolts are tight, slide joint boxes along the post insulators to final position. Close joint boxes ensuring that joint plates correctly locate into the recess in the joint boxes. Riser and Busbar Joint Plates must be fitted on all Switchboards. Figure 12 below shows a typical preparation of the joint box arrangement prior to closing. Busbar Joint Plate Riser Joint Plate Figure 12 Locating of Riser and Busbar Joint Plates into cover slots prior to strapping Joints at the ends of the busbar run are fitted with blank cover plates. Fold outer covers into position and clip locating straps through holes in the fixed section and pull to lock in position Busbar Fixing Bolts All fixing bolts are 8.8 Grade, Metric Steel M10 Fixing Bolt Lengths (All dropper sizes) Single Busbars Double Busbars Triple Busbars Quadruple Busbars 30mm 40mm 50mm 60mm For bolting together: Quantity of bolts for 700 Wide Cubicle = 12 Quantity of bolts for 1000 Wide Cubicle = 24 Notes: M10 plain and spring washer to be fitted under head of bolts into the joint casting. M10 plain washer to be fitted under head of through bolls with M10 plain and spring washer under M10 full nut. TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3 Page 25 of 53

26 Busbar Arrangements for Middle Tiers When the tier is located in the middle of a switchboard, the busbars are arranged as detailed in the diagram below: %XVEDU 5LVHU %XVEDUV 5LVHUV 3RVW,QVXODWRU %XVEDUV 5LVHUV %XVEDUV 5LVHUV %XVEDUV 5LVHUV %XVEDUV 5LVHUV %XVEDU 5LVHU Figure 13 Busbar Arrangement for Middle Tier (Side View) TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3 Page 26 of 53

27 Busbar Arrangements for End Tiers When the tier is located at the end of a switchboard, the busbars are arranged as detailed in the diagram below: %XVEDUV 5LVHUV %XVEDU 5LVHU %XVEDUV 5LVHUV 3RVW,QVXODWRU +DOI 3DFNHU %XVEDUV 5LVHUV %XVEDUV 5LVHUV %XVEDUV 5LVHUV %XVEDU 5LVHU Figure 14 Busbar Arrangement for End Tier (Plan View) TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3 Page 27 of 53

28 6.6.2 Assembly of Arc Ventilation Plenum Arc ventilation chambers (plenums) are required in order to comply with the Internal Arc Classification element of the IEC specification. Each cubicle has an individual assembly fitted into adjacent chambers. Plenums are fitted onto cubicle top covers. The assembly procedure is as follows: Fit neoprene gasket (supplied) to the plenum. Mount plenums from the left hand end of the switchboard (viewed from the front). Assemble the plenum. Note: on high current units the plenum fits over output thermal vents on the cubicle roof. Work along the length of the switchboard from the left hand end ensuring that the plenums locate. Note: Bus section plenums sometimes include dividers. Please check contract documentation and fit if required. When all the plenums are fitted, fit covers to the ends. Connect exhaust vent to the appropriate section. See contract documentation for details. TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3 Page 28 of 53

29 6.7 Torque Settings The information in contained in this section is as detailed in Torque Settings Technical Document STD/DOC/012. Description Torque Settings (Nm) Interconnections Copper/Copper M3 M4 M5 M6 M8 M10 M12 M16 M20 ISO M8.8 Grade Zinc Plated Bolt or Set-Screw Set-Screw into Brass Pillar Interconnections Steel/Steel Self Clinching Nuts (1) Self Clinching Studs (1) Welded Nut Connections to Self-Clinching Studs (Previously PEM) Flush Head Stud Connections to CT Bushings Brass Bushings Connection to ABB Surge Arrester (Aluminium) ISO M8.8 Grade Zinc Plated Bolt or Set-Screw Connection to ABB NTGU12A1 Capacitive Dividers ISO M8.8 Grade Zinc Plated Bolt or Set-Screw Lifting Beams Type 298 MV Switchgear Type 439 LV Switchgear (1) Figures shown are 75% of manufacturers torque-out data (2) Torque Application to 3 rd Party products should be in line with the manufacturers installation instructions TYPE 298 PV100 Cubicle User Guide Doc Rev 2.2 Page 29 of 53

30 Description Torque Settings (Nm) Type 439 LV Switchgear Specific Torque Settings M3 M4 M5 M6 M8 M10 M12 M16 M20 Riser/Busbar Clamp Nut Busbar Chamber Brass Pillar Nut Riser Support Cap Head Screw and Nut Outgoing Connections Outgoing Socket Connections Type 298 MV Switchgear Specific Torque Settings Stand-off insulator to support plate Brass casting to stand-off insulator Copper Fixing into Stand-off Insulator Type 298 PV100 MV Switchgear Specific Torque Settings Connection from Pole Moulding to Upper Contact Upper Contact to Vacuum Interrupter Bottle Insulated Push rod to Vacuum Interrupter Bottle Guide Pin in the Cluster Push Rod (L1, L2, L3) Locknut Seismic Bolting Down of Type 298 MV Switchgear ISO M8.8 Grade Zinc Plated Bolt or Set-Screw Seismic Bolting Down of Type 439 LV Switchgear ISO M12.9 Grade Zinc Plated Cap Head Bolt TYPE 298 PV100 Cubicle User Guide Doc Rev 2.2 Page 30 of 53

31 6.8 Electrical Connections Connection of Mains Power and Control Cables Check the contract drawings for position, number, type and direction of access for power and control cables. Remove required gland plates, covers etc. and prepare for gland installation (glands may have been ordered and supplied to contract). Cut to length and strip power cables for attachment to gland. Fit gland to cable and gland plate in accordance with gland manufacturer s instructions. Fit cable and gland plate assembly to the cubicle. Prepare and secure the cable sealing ends in accordance with the manufacturer s instructions. Pass mains cable through CBCT (where one is fitted. Refer to contract documentation.). Ensure that the earth screen from each core of the multi-core cable are connected together and passed back through the CBCT and connected to the switchboard earth bar. See Figure 15 Earth Screen Connection for details. Connect the cable cores to the connection points on the end of the current transformer bushing, ensuring that no undue stress is applied to the bushing. Fit cable termination covers over the bushings, slot sub-cover in position and attach with rivet clips. Connect cable earth. Strip and fasten the control cables to the multi-core box gland plate with glands in accordance with manufacturer s instructions. Fit cable and gland plate assembly to multi core box. Terminate individual cores in compliance with the circuit diagram. Make the control wiring connections to adjacent panels via bus wiring access holes in the instrument chambers. Figure 15 Earth Screen Connection Earthing the Switchboard Ensure the cable earth is connected. Connect the main earthing bar of the switchgear to the prepared connection links, panel by panel. Make the earth connection to the foundation frame or the raised false floor. Connect the earthing conductor from the ground electrode, preferably via a metering point, to the main earthing bar of the switchboard. TYPE 298 PV100 Cubicle User Guide Doc Rev 2.2 Page 31 of 53

32 6.9 Final Installation Check the paintwork of the switchgear for any damage, and touch up where necessary. Check bolted connections; especially all those made during on-site assembly in the busbar and earthing systems, and tighten to the specified torque where necessary. Carefully clean the switchgear. Remove all foreign bodies from the switchgear panels. Properly refit all covers etc., removed during installation and connection. Fit unit end covers to switchboard end panels. Please ensure that all insulation barriers and additional barriers for extended depth cubicles are fitted. Ensure all external holes into the chambers are blanked off with the correct plugs, screws, covers etc. Check the isolating contacts and interlock mechanisms for smooth operation. Remove protective caps etc. from circuit breakers (refer to relevant circuit breaker manuals). Insert the withdrawable elements/power modules into the switchgear and control gear panels, ensuring that each one is placed in the correct location, according to its rating, and is in compliance with the general arrangement layout drawing. Close and lock all front and rear doors. Carry out full mechanical interlock checks. Refer to Section 9.4 Electro-Mechanical Interlock Checks for further details. TYPE 298 PV100 Cubicle User Guide Doc Rev 2.2 Page 32 of 53

33 6.10 Extension Cubicles Type 298 equipment is designed to allow extension cubicles to be fitted as required to either end of the switchboard. The following procedure describes the work that needs to be carried out. De-energise the busbars in full accordance with the site shutdown and permit to work requirements Remove the panel end covers on the existing switchboard If extending on the right hand end: Remove the busbar insulation barrier and replace with appropriate half high or cut-out barrier. If extending on the left hand end: Remove the busbar insulation barrier and dispose of as the appropriate on is already fitted to the extension tier. Move the extension cubicle(s) onto the prepared foundations in the order detailed on the revised General Arrangement drawing. Movement can be accomplished using floor rollers (maximum diameter 12mm) between the cubicle base plate and the site floor. Ensure each section is correctly positioned relative to the neighbouring cubicle. It is essential to ensure correct alignment of the front face of the switchboard. Bolt the cubicles together, noting that the insulation retaining strips are to be positioned between the cubicles to provide partitioning between compartments. Fasten the extension cubicle(s) to the foundation fixings. Open the rear cable chamber door of the outer most cubicle on the originally installed Switchgear. Remove the vertical bus bar chamber cover. Remove the bolted end plate from within the bus bar chamber to expose the bus bar aperture into the extension cubicle. Fit the extension bus bars & busbar seals. Re-fit the bolted end plate internally within the outer most bus bar chamber cubicle. Replace all vertical bus bar chamber covers and close the rear cable chamber doors. Re-fit the insulation barriers (if required) and end covers on the outer most cubicle ends. Re-commission the bus bar system in accordance with Section 7 Pre-Commissioning of this manual. TYPE 298 PV100 Cubicle User Guide Doc Rev 2.2 Page 33 of 53

34 7 Pre-Commissioning 7.1 Overview For the purpose of this manual, the term Pre-Commissioning refers to the work that is carried out to ensure that the equipment operates as per the contract requirements. This includes post-installation testing and the set-up of equipment such as protection relays in order that they functionally operate as intended by the electrical schematics. More detailed commissioning work that concerns the detailed operation of the plant is not covered by this document It is recommended that all pre-commissioning work is carried out by Powell UK personnel and also that Powell UK personnel assist with the detailed commissioning work. Please contact the Site Services team for further information regarding both pre-commissioning and commissioning personnel and site activities. 7.2 Pre-connection Checks In preparation for pre-commissioning, the following work should be carried out prior to connection of the highvoltage power supply: General and Visual Checks Check the general condition of the switchgear for damage of any kind. Remove all material residues, foreign bodies and tools from the switchgear. Clean the switchgear, rubbing down insulating parts with a clean, soft, non-fraying dry cloth. Remove greasy or adhesive dirt with a cloth dampened with a slightly alkaline household cleaner. Wash off with clean water and dry carefully. Perform a visual examination of the withdrawable elements, power modules, isolating contacts, insulating parts etc. For systems with a BIL of 95kV, check the correct fit and location of the additional parts required to ensure compliance with the rated insulation level of switchgear panels, in line with the contract documentation. Visually check the connection of the main earthing bar to the station earthing conductor. Check all busbar connections have been torqued to the correct level. Check all busbar joints have been fitted with appropriate boots and shrouds Control Wiring Completion Checks Carry out a point-to-point wiring check of the tier interconnection wiring. Ensure all connections are tight and that the cable marker is visible Low Ohm (Ducter) Tests (Minimum 50A) Perform a Low Ohm test through all closed and connected circuit breakers. Perform a Low Ohm test through all closed and connected mechanically operated earth switches. Perform a Low Ohm test through all busbars Primary Injection Tests Perform a primary injection test on the current transformers. Perform a primary injection test on the voltage transformers. These tests are optional. Primary injection testing is carried out on all voltage and current transformers in the factory and it is at the client s discretion whether these tests should be carried out again on site Secondary Injection Tests Perform a secondary injection test on all protection relays. Perform a secondary injection test on all metering relays. Note: Test voltage must match the system voltage TYPE 298 PV100 Cubicle User Guide Doc Rev 2.2 Page 34 of 53