Specification for LV Distribution Fuse Board (Feeder Pillar

Specification for LV Distribution Fuse Board (Feeder Pillar)
EP-MS-P4/S2-010
EP-MS-P4/S2-010
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EP-MS-P4/S2-010
Document Control
Department Document Type Material Specification Standards Issue Approval Prepared By
Consultant M/s. Ewbank Preece Limited
Member of the Mott Mac Donald Group,UK Material Standards & Specification Engineer Signature: Signature:
Document Title EP-MS-P4/S2-010 Specification for LV Distribution Fuse Board (Feeder Pillar)
EP
Approved By
Head of Design & Development Manager, EN Planning Dept.
Issue Record
Issue No. 0.0 1.0 2.0 3.0 4.0 5.0 Date
30.04.2003 02.10.2008 26.01.2012
Reason for re-issuing Document

First issue of Materials Specification Standards Review of Materials Specification Standards Review of Materials Specification Standards
Key Words Review Frequency
: :
Every 3 years
When this document is approved for publishing on the intranet, a copy of its Document Control page should be sent to the QA section who is custodian of KM quality management system.
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1.0
Scope This specification details about requirements for design, manufacture testing, packing, transport and supply of LV Distribution Fuse Boards for use in Outdoor Sub-stations for 11 kV Distribution Networks for which supply low voltage, with separate neutral and earth in the state of Qatar a) Pillar mounted fuse boards, cable connected, subsequently referred to as FEEDER PILLARS. Transformer mounted fuse boards in cabinets, subsequently referred to as FUSE CABINETS.
b)
The fuse boards are for use on 3 Phase, 4 wire AC systems at a frequency of 50Hz and at a nominal voltage of 415 V between phases. 1.1 REFERENCES This Standard makes reference to, or should be read in conjunction with, the following documents : IEC 60269/BS 88-5 Cartridge Fuses for Voltages up to and including 1000V AC and 1500V DC, Part 1, General Requirements. Low-Voltage Switchgear and Control Gear Assemblies. Specification for Colours for Identification, Coding, and Special Purposes. Cartridge Fuses for AC Circuits in Domestic and Similar Premises. 13A Plugs, Switched and Unswitched Socket-outlets and Boxes. Metallic and other inorganic coating. Thermal spraying. Zinc, Aluminium and their alloys. Electroplated Coatings on Threaded Components. ISO Metric Precision Coatings on Threaded Components.
IEC 60439/1 & 5 BS 381C
IEC 60269/BS 1361
BS 1363
BS EN 22063:1994
BS 3382 ISO 272/4759/BS 3692
IEC 60044-1(1996)/ BS 7626:1993 ISO 885/ISO 4759/1 BS 6001

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Current Transformers.
ISO Metric Black Hexagonal Bolts, Screws and Nuts. Sampling Procedures and Tables for Inspection by Attribute.
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BS 6231:1998
Specification for PVC Insulated Cables for Switchgear and Control Gear Wiring. Impregnated Paper Insulated Cables for Electricity Supply. Power Transformers Specification for Cable Boxes for Transformer and Reactors.
BS 6480/IEC 60055 IEC 60076 BS 2562:1993 2.0
ENVIRONMENTAL CONDITIONS The LV Distribution Boards will generally be installed in outdoor situations in a tropical climate having the following characteristics: 1. Altitude: Low lying, generally close to sea level - no point exceeding 100 metres above sea level.
2.
Temperature: Air maximum 50C (460 C typical) Air minimum 0C (100C typical) Air maximum mean average 45C Air minimum mean average 10C Exposed sunlight 75C maximum.
3. 4.
Solar Radiation Peak 1030W/sq.m. Humidity: Ranges between 30% and 100%, though 100% is common throughout the year and may occur at air temperatures in excess of 30C.
3.0
THE LOW VOLTAGE DISTRIBUTION BOARD (FEEDER PILLAR) 1. General Design & Constructional Features
3.1.1 This Standard covers arrangements of feeder pillars, as described below, suitable for use with: a) b) 500, 800, and 1000 kVA Transformers 1250 and 1600 kVA Transformers.
3.1.2 Transformers are oil filled and in general accordance with IEC 60076. LV Interfaces are generally in accordance with BS 2562, specific detail being provided in this Specification. 3.1.3 The feeder pillars shall be complete with supporting members as required on which shall be mounted control equipment, busbars and instrumentation in accordance with the arrangements specified below. The design shall be such that the cables can be readily jointed from the front. 3.1.4 All parts of the distribution equipment shall, as far as practicable, be readily accessible and replaceable without excessive dismantling.
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3.1.5 Insulating materials shall be as nearly non-hygroscopic, resistant to tracking and self-extinguishing as present good manufacturing technique permits. 3.1.6 All metallic parts including (but not limited to) bolts, nuts, washers, hinges latches shall be of stainless steel material. Where live metal work is adjacent to the framework a sheet of bakelite or other suitable low voltage insulating material shall be fixed to the inner side walls of the feeder pillar and shall extend to at least 200mm above the red phase (upper phase) top contacts and an equal distance below the blue phase (lower phase) bottom contact. The width of the insulating sheet shall approximate to that of the side walls of the feeder pillar and the thickness shall not be less than 2.0mm.The sheet of insulating material shall be suitably fixed. The fixing shall not incorporate metallic parts which protrude towards live metalwork. If adhesives are used, the quality shall be such as to ensure proper adhesion under the temperature/humidity levels described earlier. 3.1.7 All parts of equal size and rating shall be inter-changeable. The general design shall be such that the number of joints shall be kept to a minimum. All bolted joints shall be secured by corrosion proof steel bolts. All bolts and studs shall be plated to BS 3382 and shall have corrosion proof locking features. Each distribution unit position shall be drilled for mounting at 145 5 mm centers. 3.1.8 The design & construction shall generally conform to the latest versions of IEC 60439-1 and IEC 60439-5, and Technical specification # 37-2 of Energy Network Association. 3.1.9 The feeder pillars shall be designed to take up the following arrangements: - 2500 A Busbars - 2500 A incoming transformer unit: - Nominal size of incomer cables up to 7 Nos. of 800 sq.mm. - 6 Nos. 630A outgoing distribution units. - Instrument panel. The framework shall be arranged to accommodate the equipment in the following order reading from the front, left to right: Distributor units Transformer unit Instrument panel 3.1.10 The FP shall be constructed only of materials capable of withstanding the mechanical, electrical and thermal stresses as well as the effects of humidity which are likely to be encountered in normal service. The insulating materials used for barriers, and other insulating parts shall have resistance to thermal stress and flame retardant properties in accordance with clause 8.2.102 of IEC 604395. 3.1.11 Protection against corrosion shall be ensured by the use of suitable materials or by the application of equivalent protective coatings to the exposed surface, taking into account of the intended conditions of use and maintenance. The materials of coating shall pass the appropriate tests of clause 8.2.103 of IEC 60439-5.
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3.1.12 The housing of the FP shall be robust construction, and manufactured from sheet steel. Its mechanical properties shall comply with the requirements specified under clause 8.2.101 of IEC 60439-5. 3.1.13 IP protection of FP enclosure shall not be less than be IP 41 in closed door condition. However, adequate ventilation shall be provided to permit natural circulation of air. The ventilation apertures shall be covered with corrosion-proof metallic screens to prevent entry of vermin and other foreign bodies and ingress of water. 3.1.14 Access to the front of the FP cabinet shall be through double leaf triple hinged door, fitted with a locking bar to secure them top and bottom. The locking bar shall be operated by a single robust handle which shall be arranged to permit locking by a padlock with a 52 x 49mm body, 8.5mm diameter shackle, having a clear inside width of 29mm and inside length of 41 to 55mm. The holes provided for the shackle shall be not less than 10mm diameter. For adequate illumination of cabinet, a heavy duty LED lamp with limit switch shall be provided inside the feeder pillar which interlocked with door open/close operation. All gaskets for doors shall be of superior quality and withstand the mentioned climatic conditions. 3.1.15 The FP cabinet shall be designed to ensure that adequate clearances shall be provided to permit closing & locking of main doors, even when the incoming transformer circuit isolators blades are fully left in an open or closed position, and pad locked with its protection cover. 3.1.16 The front apron plate, along with any associated structural members, at cable entry point of the cabinet, shall be removable type to facilitate easy installation or reshuffling of outgoing units cables. Rear access to the cabinet shall not be provided. 3.1.17 The design shall be such that cables can be terminated from the front through bottom entry. All Parts of equal size and rating shall be interchangeable. The general design shall be such that the number of joints shall be kept to a minimum. Corrosion proof (with electro-nickel plated) steel bolts shall be used for electrical joints. All bolts and studs shall be plated to BS 3382 and shall be corrosion proof. 3.1.18 Bus-bars shall be situated at the rear of the equipment. Bus-bars shall be made of nickel/tin-plated high conductivity electrolytic copper and un-insulated. There will be sharp edges on the entire bus bar. Phase bus-bars shall be colour marked (at least 25 mm shrinkable insulating tubes) in sequence from top to bottom as red, yellow, blue and the neutral bus-bar shall be marked as black. There shall no mark on the earth bus-bar mounted at the. Earth bus-bar shall be mounted below the bottom plate (not above base plate) and a suitable bolt to be provided for the connection of earthing bus bar to earthing rod. 3.1.19 All metal works including internal steel work shall be securely bonded in a way to ensure perfect connections between the parts, components and earth rod. 3.1.20 A bolted link-bar of same rating as neutral bar, shall be provided between the neutral and earth bus-bars. The metal framework of the fuse cabinet shall be bonded to the earth bar.
EP-MS-P4/S2-010
3.1.21 Where live metal is adjacent to the framework a sheet of Bakelite or other suitable low voltage insulating material shall be fixed to the inner side walls of the fuse cabinet. It shall extend to at least 200mm above the red phase (upper phase) top contact and an equal distance below the blue phase (lower phase bottom contact). The thickness of the insulating material shall not be less than 2.0mm. The width of the insulating sheet shall approximate to that of the sidewall of the fuse cabinet. The sheet of the insulating material shall be suitably fixed. The fixing shall not incorporate metallic parts, which protrude towards live metal work. If adhesives are used, the quality shall be such as to ensure proper adhesion under the temperature/humidity conditions stated in this Specification. 3.1.22 Insulated dividing barriers shall be provided between incomer unit, outgoing distributor units and instrument panels. The fixing of the insulated dividing barriers shall be such that they shall not swing. 3.1.23 All CTs should be complied with thermal class insulation F. 3.1.24 Two small cable entry holes fitted with M25 brass compression glands, to be made on the bottom plate at right side front corner. This is required to connect auxiliary cables and output cable from REF relay protection. 4.0 Incomer Unit with Switch-Disconnector (for transformer Control) 4.1 The incomer unit consists of 3 independent single pole switch-disconnectors, each pole independently operated through insulated operating handle. Each pole corresponds to matching phase of the incoming transformer circuit. The incomer switch-disconnetor unit shall be a type tested product conforming to the requirements of IEC 60947-3 & IEC 60947-1. It shall be dependent manual operated, with utilization category of AC21A. Making and breaking capacities shall be at least 1.5 times its rated operational current. Product type test certificates, issued from reputed independent laboratory shall be submitted for verification. The switch-disconnector contacts shall include a contact-tightening device on both the top fixed contact, the bottom hinged contact, designed to obviate slackening when subject to vibration, and good contact shall not depend upon the neutral spring of the contact. Reasonably good contact shall be made on closing the switch so that the full current can be safely carried in the interval prior to the tightening of the contacts The contact tightening device shall be operated by crank action using the insulated operating handle; the same end of the operating handle shall be used for tightening or slackening the contact tightening device as is used for opening or closing the switch-disconnector blades. When the device is being tightened or slackened the operating handle end shall remain in the device. The total movement of the contact tightening device, from full slackness to full tightness, shall not be more than 140 of angular rotation. ISOLATING MOVING BLADES SHOULD REMAIN IN ITS POSITION WITHOUT DROPPING BY ITS OWN WEIGHT, EVEN IN OPEN POSITION. Each switch-disconnector pole shall be equipped with transparent polycarbonate safety barrier at front, with pad-locking facilities. Pad-locking shall be possible
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4.2
4.3
4.4
4.5
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when the switch contacts are either in fully open or closed positions. When the switch contact blade is in fully opened condition, the blade shall not touch the front safety barrier, and shall have at least 50mm clearance. It shall be possible to close main door of the FP when the contact blade is fully opened and padlocked. 4.6 4.7 Each phase and neutral of the incomer unit shall be colour marked to correspond with the bus-bars to which they relate. The insulated operating handle shall be kept in the slots of clips provided on the framework to store this when not in use. The amount of bare metal on the pole shall be kept to a minimum. Each switch-disconnector pole shall be equipped with one current transformer (details specified elsewhere). It shall be possible to easily change current transformers, without dismantling any major components. A bolted link of not less than 1250A rating shall be provided to disconnect the neutral. Robust and rigid insulated dividing barriers, of not less than 5mm thickness, shall be provided between each pole of incomer unit. The fixing of these insulating dividing barriers shall be such that under normal operating conditions it is not possible for contact to be made between live metalwork of different phases or between live and earthed metalwork.
4.8
4.9 4.10
5.0
Outgoing Distributor units 5.1 Each distributor unit shall be drilled for mounting at 145 +5mm centres apart. It shall be possible to change any single bus-bar or cable connection without affecting other phases. Contact assemblies shall be supported from the steel frame-work by means of strips, rods, bars or mouldings of insulating materials. The arrangement of supports shall be such that mechanical stresses produced in service by the temperature rise of connections shall not adversely affect the alignment of the contact surfaces. The fixed contact assembly shall be suitable for accommodating a fuse carrier with a 92 mm terminal centre fuse-link type 'J' in accordance with BS 88. Fuse carriers shall be supplied with the pillars. Each fuse carrier shall be suitable for inserting in a phase of the unit by hinge action pivoted on the lower contact and for withdrawing by snatch action. The contacts shall be arranged to permit contact tightening and the contact surfaces shall be flat, accurately aligned in pairs and no sharp edges. The phase cable side fuse contacts shall be designed with long and short reach and shall be fitted with forward projecting M16 captive steel studs, one per contact complete with a full nut. A lock washer, and plain washer with lock nut shall be provided. The contacts shall be so designed that they provide adequate spacing and are fully interchangeable to permit terminating the phase conductors of a cable whatever their lay.
5.2
5.3
5.4
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5.5
The phase cable side contact groove (for receiving the fuse) shall be centrally and symmetrically placed, so that, even if this contact is fixed in reverse side, its fixing centre shall not miss its alignment for fixing fuses. Further, if these contacts are made in L-shape, the gap between adjacent contacts, when fitted in reverse directions, shall be at least 60mm. Alternatively, if these contacts are made in I shape, these contacts shall be fitted with additional copper spacer rings of 6mm thickness, so that the outgoing cable insulation will not touch the hot bus-bars, when connected. Insulated dividing barriers shall be provided between phase contact assemblies and phase and neutral contact assemblies which shall make it impossible to insert a fuse link between contacts of different phases. There shall be no separate neutral isolating link on each outgoing unit. The neutral conductor of each cable (of outgoing unit) shall be terminated on to a contact bar, rated at 315A, mounted below the corresponding outgoing distributor unit, between the neutral bus-bar and the insulated support strut. The bottom fixing of the insulated support strut shall be mounted above the neutral contact bar so as to allow the neutral core an unimpeded approach to the desired fixing position. This neutral contact bar shall be drilled in two positions and fitted with a high tensile M16 steel bolt, nut, and lock-washer or plain washer with locknut shall be provided. The neutral bus-bar shall be fitted 460mm above the centre line of cable cleats at bottom. Bottom plate of the feeder pillar with cable entry holes, shall be divided into two portions. By removing the front portion, and front apron plate, it shall be suitable to connect, disconnect, or interchange any cable connection. All holes shall be closed with dummy plates which are removable at the time of connections. Cable entry holes shall be fitted with suitable sizes of Brass Wiping Glands conforming to BS 2562 size: X and size: Y. Wooden Cleats, if any, provided shall be in addition to the Brass Wiping Glands. Brass Wiping Glands shall need to ensure that the bending moment coming through the Cable. Laying, shall not be transferred to connecting terminals. The cleat shall clamp directly on to the PVC over sheath of the cable. The cable cleat and its fixings shall be adequate to support the outgoing cable in normal service and when subjected to the short circuit duty specified elsewhere. Cable termination arrangement shall be suitable for accommodating up to and including 300mm 4 core stranded copper conductor either paper insulated lead sheathed double steel tape armoured PVC over sheathed cables to BS 6480 or XLPE insulated steel wire armoured PVC over sheath of the cable as per IEC 60502. Required number of holes shall be drilled on earth bar and fixed with M16 bolts, nuts & washers, for terminating Cable earths from each out going cable. All cable connections shall be suitable for terminating using heat shrinkable materials and crimping lugs. (Heat shrink terminations & cable lugs are not in the scope of supply).
5.6
5.7
5.8
5.9
5.10
5.11
5.12 5.13
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5.14
Provision shall be made on each outgoing feeder ways to affix and padlock a suitable insulated device to prevent fuse links being installed or removed. Two such devices shall be provided with each feeder pillar. The device shall not obstruct the feeder pillar doors from closing when in position or when stored within the feeder pillar. It is essential that the device can be safely fitted whilst the pillar and each feeder is alive. The device shall be marked with the following wording in English and Arabic and be clearly visible when viewed from the front with the feeder pillar doors open: "CAUTION -MEN WORKING - DO NOT INTERFERE WITH THIS APPARATUS
5.15
5.16
Blank circuit labels suitable for engraving black letter on white background shall be provided for all outgoing circuits. The support for the circuit labels shall not be on any live part.
6.0
Electrical Ratings & Characteristics 6.1 Rated operational voltage (Ue) Rated insulation Voltage (Ui) Rated impulse withstand voltage (Uimp) Rated frequency : 415/240Vac : 690Vac : 8kV : 50 Hz
Restricted Earth Fault (REF) Tripping Mechanism a) The purpose of REF Protection relay is to trip the 11kV side of the Transformer Switch or from the REF scheme on LV side of Transformer, in which CTs are provided in the feeder pillar, which Protect during an earth fault within in the protected zone of the scheme, i.e. LV winding up to the CT location. b) The scheme shall have 4 Nos. of class X CTs (1 for each phase and 1 for neutral) and shall be mounted inside the feeder pillar, The replacement of CT (if needed), shall not affect any of the connection or disconnection on income or outgoing cables and replacement of contacts. c) The secondary of all these CTs shall be connected in parallel (i.e. the same polarity terminals connected together ) for the REF scheme, and shall be connected to electro-mechanical type REF relays (like CAG14 or equivalent approved by KAHRAMAA) through stabilizing resistance of proper rating. d) The REF relay terminals shall be easily accessible for checking on load current and tightness. e) All the CTs used for the REF scheme shall have same ratio, magnetization characteristics, winding resistance, etc.and shall be from same manufacturer. The knee point voltage of CTs must be higher than the stabilization voltage for maximum external fault current.
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f) Current Transformers shall be rated 2500/5 Amp for 2500 Amp rated and 1600/5 for 1600 Amp rated feeder Pillars. g) To achieve stability during external fault, proper short time rated variable stabilizing resistor shall be provided in series with the REF relay. The stabilizing resistor shall be easily accessible and shall be easily replaceable. Same methodology for REF scheme calculation shall be adopted for the above. h) Provision to gland PVC insulated, sheathed and armored 2x 2.5 sq.mm copper cable for Inter tripping shall be used for interconnecting the trip wires from Feeder Pillar to 11kV transformer control switch (in general). i) Terminal Blocks having isolating link and CT shorting facility shall be used at feeder pillar and 11kV switchgear for terminating secondary wires of CTs. The single point earthing of CT secondary circuit shall be confirmed. j) The Trip wires from the REF relay in the feeder pillar shall be terminated on TBs having isolation links. This TBs shall be properly labeled (such as REF int. trip) and shall be provided with proper identification ferrules. k) All wires shall be provided with ferrules for identification. For example, wires at CT terminals shall be ferruled as S1 and S2. l) The scheme shall be tested for, CTs to prove ratio, polarity, magnetization curve and winding resistance, ratio checks for confirming that the installed CTs are adequate for the REF scheme and also the stability checks and Tripping shall be proved. m) Sensitivity of the scheme shall be tested by Primary injection. Also the stability of the scheme shall be tested for external faults (Balancing and unbalancing and the results shall be provided. n) Certification with test results complying above requirements shall be provided with each unit. o) For Intertripping the RMU to operate the shunt coil of RMU 24 V long life battery shall be installed in the feeder pillar and the battery supply shall be connected through the REF relay contact and connected on proper terminals. Location of battery shall be at front top on the feeder pillar within a suitable fabricated lockable box. 6.2 REF data for 2500 AMP Rated Feeder Pillar Current Transformer Ratio 2500/5 Class X Winding resistance at 75 Degree <0.75 Ohm Stabilizing resistance 0 to 50 Ohm (variable) Set at 50 Ohm Knee Point voltage Not less than 125 V For this values, transformer capacity is 1600 KVA and at 6% Impedance
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6.3
REF data for 1600 AMP Rated Feeder Pillar Current Transformer Ratio Class Winding resistance at 75 Degree Stabilizing resistance Knee Point voltage 1600/5 X <0.4 Ohm 0 to 50 Ohm (variable) Set at 40 Not less than 75 V
For this values, transformer capacity is 1000 KVA and at 5.5% Impedance. If any variation in the offered values other than the above, the supplier should derive the knee point voltage and the value of stabilizing resistance from the below formula given below. 6.4 For Stable Operation of the REF relay the following condition should be satisfied Iop (Rst + Rr) Where Iop Rst Rr IFs IF Ifs Rl IF 6.5 = Relay Setting Current Value of Stabilizing Resistor Resistance of Relay at Current Setting Maximum Secondary Current during the fault Maximum Fault Current IF/ CT ratio Resistance of CT loads TX capacity / 3 V x pu Impedance > Ifs (Rct + 2 Rl)
CT knee point requirement calculation Vkp = 2 x Iop (Rst+Rr+2RL) Minimum VKp should be as above equation Where Vkp Iop Rst Rr 2RL = Minimum knee joint voltage
= Relay setting current = Stabilizing resistor = Relay resistance = Loop resistance
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7.0
Rated Normal Currents Rated normal Rated normal current of Incomer current of Phase units * Bus-bars * 800A 800A 1600A 1600A 1600A 1600A 2500A 2500A No. of outgoing Ways in FP 2 4 6 6 Rated normal current rating of each Outgoing unit * 630A 630A 630A 630A
*These ratings have reference to local ambient conditions stated in the Specification. 8.0 Rated short circuit withstand current and Peak withstand currents. Rated normal current of Incomer units 800A 1250A 1600A 2500A 9.0 Rated Short circuit withstand current (Icw) 20kA @ 1 Sec 20kA @ 1 Sec 35.5kA @ 1 Sec 40 kA @ 1 Sec Rated peak withstand current (Ipk) 50kA 50kA 88 kA 100kA
Clearances For all connections in air the clearance and creepage distances shall be not less than 60mm between conductors and 50mm from conductors to earth. Temperature Rise Limits The distribution fuse-board shall be so designed as to ensure that thermal interaction does not unduly affect the performance of any of the components Temperature rise test on the FP shall be conducted in accordance with clause 8.2.1.3 of IEC 60439-1 (by using current on all apparatus) with all its components, including fuselinks, fitted, and all circuits are fully loaded. The test shall be carried out with the base closed, door(s) shut and mouth of the throat piece through which pass the incoming connections, shall be effectively blanked off. All the measurements shall be taken with the help of thermocouples and thermometers. The FP shall be capable of withstanding the guaranteed temperature rise limits specified in IEC 60439-1/ cl# 7.3/Table-2. However actual temperatures rises of over ambient temperature outside the FP shall not cross the limits as specified below. Sr.No 1 2 3 4 5 6 7 Part/component of the Assembly All temporary incoming connections Interconnecting point between Tx and FP Top contacts of each phase of the isolator Top contacts of each phase of O/G fuse units All cable lugs/terminals All bus-bars All other built-in components Temperature rise limits, K
10.0
45
In accordance with limits specified in relevant product standards requirements, less 250K
Evidence shall be submitted that temperature rise tests have been carried out on a completed FP, to demonstrate that it does comply with this Clause.
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11.0
Cleaning and Painting The following is the minimum standard. Manufacturers may offer an alternative, at the time of tender. A ferrous surface and edges shall be cleaned of scale and rust by shot blasting and shall then be treated on the same day, without outdoor exposure, with a zinc spray. The zinc shall be applied by flame gun process of a thickness ZN4 in accordance with BS EN 22063 : 1994. The treatment shall be followed by application of one coat of zinc chromate base priming paint, an undercoat and final coat of durable oil and weather resisting paint. The final coat shall be dark admiralty grey colour 632 in BS 381 C.
12.0
Overall Dimensions (Max) : with REF Relay Width 1800 Depth 600 Height-1800 The Foundation Bolts are out side
13.0
Fuse Cabinets (Bolt on Feeder Pillars) 13.1 General This Specification covers arrangements of fuse cabinets as described below suitable for use with 500, 800 and 1000 kVA transformers to IEC 60076. The fuse cabinets shall be complete with supporting members as required on which shall be mounted an incoming transformer unit and outgoing distributor units with busbars, and an instrument panel, in accordance with the specified arrangements. The design shall be such that the cables can be readily jointed from the front. All parts of the distribution equipment shall, as far as practicable, be readily accessible and replaceable without excessive dismantling.
13.1.1 Insulating materials shall be as nearly non-hygroscopic, resistant to tracking and self-extinguishing as present good manufacturing technique permits. 13.1.2 All metallic parts including (but not limited to) bolts, nuts, washers, hinges latches shall be of stainless steel material. 13.1.3 All parts of equal size and rating shall be inter-changeable. The general design shall be such that the number of joints shall be kept to a minimum. All bolted joints shall be secured by corrosion proof steel bolts. All bolts and studs shall be plated to BS 3382 and shall have corrosion proof locking features. Each distribution unit position shall be drilled for mounting at 145 5 mm centres. 13.1.4 Provision shall be made for supporting the lower half of the cabinet by two adjustable supports that shall bear against the tank of the transformer when the cabinet is in position. These shall be adjustable in length from inside the cabinet and shall have end caps to prevent damage to the transformer paintwork.
EP-MS-P4/S2-010
13.1.5 The feeder pillars shall be designed to take up the following arrangements: 1600 A Bus bar 1600 A incoming transformer unit: 4 Nos. 630A outgoing distribution units. Instrument panel.
The distributor units shall be mounted side by side with the red, yellow and blue phase fuses mounted below one another. 13.1.6 The FP shall be constructed only of materials capable of withstanding the mechanical, electrical and thermal stresses as well as the effects of humidity which are likely to be encountered in normal service. The insulating materials used for barriers, and other insulating parts shall have resistance to thermal stress and flame retardant properties in accordance with clause 8.2.102 of IEC 60439-5. 13.1.7 Protection against corrosion shall be ensured by the use of suitable materials or by the application of equivalent protective coatings to the exposed surface, taking into account of the intended conditions of use and maintenance. The materials of coating shall pass the appropriate tests of clause 8.2.103 of IEC 60439-5. 13.1.8 The housing of the FP shall be robust construction, and manufactured from sheet steel. Its mechanical properties shall comply with the requirements specified under clause 8.2.101 of IEC 60439-5. 13.1.9 IP protection of FP enclosure shall not be less than be IP 41 in closed door condition. However, adequate ventilation shall be provided to permit natural circulation of air. The ventilation apertures shall be covered with corrosionproof metallic screens to prevent entry of vermin and other foreign bodies and ingress of water. 13.1.10 Access to the front of the FP cabinet shall be through a triple hinged door, fitted with a locking bar to secure them top and bottom. The locking bar shall be operated by a single robust handle which shall be arranged to permit locking by a padlock with a 52 x 49mm body, 8.5mm diameter shackle, having a clear inside width of 29mm and inside length of 41 to 55mm. The holes provided for the shackle shall be not less than 10mm diameter. For adequate illumination of cabinet, a heavy duty LED lamp with limit switch shall be provided inside the feeder pillar which interlocked with door open/close operation. All gaskets for door shall be of superior quality and withstand the mentioned climatic conditions.
13.1.11 The FP cabinet shall be designed to ensure that adequate clearances shall be provided to permit closing & locking of main door, even when the incoming transformer circuit isolators blades are fully left in an open or closed position, and pad locked with its protection cover. 13.1.12
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The front apron plate, along with any associated structural members, at cable entry point of the cabinet, shall be removable type to facilitate easy installation
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or reshuffling of outgoing units cables. Rear access to the cabinet shall not be provided. 13.1.13 The design shall be such that cables can be terminated from the front through bottom entry. All Parts of equal size and rating shall be interchangeable. The general design shall be such that the number of joints shall be kept to a minimum. Corrosion proof (with electro-nickel plated) steel bolts shall be used for electrical joints. All bolts and studs shall be plated to BS 3382 and shall be corrosion proof. 13.1.14 Bus-bars shall be situated at the rear of the equipment. Bus-bars shall be made of nickel/tin-plated high conductivity electrolytic copper and un-insulated. There will be sharp edges on the entire bus bar. Phase bus-bars shall be color marked (at least 25 mm shrinkable insulating tubes) in sequence from top to bottom as red, yellow, blue and the neutral bus-bar shall be marked as black. There shall no mark on the earth bus-bar mounted at the. Earth bus-bar shall be mounted below the bottom plate (not above base plate) and a suitable bolt to be provided for the connection of earthing bus bar to earthing rod. 13.1.15 All metal works including internal steel work shall be securely bonded in a way to ensure perfect connections between the parts, components and earth rod. 13.1.16 A bolted link-bar of same rating as neutral bar, shall be provided between the neutral and earth bus-bars. The metal framework of the fuse cabinet shall be bonded to the earth bar. 13.1.17 Where live metal work is adjacent to the framework a sheet of bakelite or other suitable low voltage insulating material shall be fixed to the inner side walls of the feeder pillar and shall extend to at least 200mm above the red phase (upper phase) top contacts and an equal distance below the blue phase (lower phase) bottom contact. The width of the insulating sheet shall approximate to that of the side walls of the feeder pillar and the thickness shall not be less than 2.0mm.The sheet of insulating material shall be suitably fixed. The fixing shall not incorporate metallic parts which protrude towards live metalwork. If adhesives are used, the quality shall be such as to ensure proper adhesion under the temperature/humidity levels described earlier. 13.1.18 Insulated dividing barriers shall be provided between incomer unit, outgoing distributor units and instrument panels. The fixing of the insulated dividing barriers shall be such that they shall not swing. 13.1.19 All CTs should be complied with thermal class insulation F. Two small cable entry holes fitted with M25 brass compression glands, to be made on the bottom plate at right side front corner. This is required to connect auxiliary cables and output cable from REF relay protection.
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13.2
Incoming Transformer Unit The rated normal current of the incoming circuit shall be 1600A. Hard drawn, high conductivity copper connections or other material approved by the Purchaser, with provision for adjustment, shall be provided between the transformer LV stems and the terminals of the isolators and neutral link. These connections shall be suitable for connecting to the appropriate terminals shown in Drawing EP-MS-02-010 Figs 4 and the 1600A connections shall be arranged so as to be bolted at both the front and rear positions on the transformer LV stems. The rated normal current of the phase connections shall be 1600A as required, the neutral connection being rated at not less than one half of that of the phase connections. Each phase and neutral of the transformer unit shall be colour marked to correspond with the busbars to which they relate. A pole operated isolator shall be provided in each phase of the incoming transformer circuit. See Drawing EP-MS-P4/S2-010 Fig 1. The isolator contacts shall include a contact tightening device on both the top fixed contact and the bottom hinged contact, designed to obviate slackening when subject to vibration and good contact shall not depend on the neutral spring of the contact. Reasonably good contact shall be made on closing the isolator so that the full current can be safely carried in the interval prior to the tightening of the contacts. The contact tightening device shall be pole operated by crank action using the isolator operating pole; the same end of the operating pole shall be used for tightening or slackening the contact tightening device as is used for opening or closing the isolator. When the device is being tightened or slackened the operating pole end shall remain in the device. The total movement from full slackness to full tightness of the device shall be confined to angular rotation of not more than 140 in one movement. An insulated pole shall be provided for operating the isolators, and clips shall be provided inside the cabinet to store this when not in use. The amount of bare metal on the pole shall be kept to a minimum. Provision shall be made on each phase for one current transformer as specified in Section 11, "Current Transformers". It shall be possible to easily change current transformers and should be securely fixed without touching the live conductor. A bolted link of not less than 800A rating shall be provided for disconnection of the neutral. The incoming transformer unit, which shall be mounted horizontally, shall be fully shrouded with insulating material on the sides and at the front. The front shall be hinged and be of transparent material. Facilities shall be provided for locking the cover in position.
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Insulated dividing barriers shall be provided between phase contact assemblies and between phase and neutral contact assemblies. 13.3 Outgoing Distributor Units The rated normal current of outgoing circuits shall be 4X630A. Cable termination arrangements shall be suitable for accommodating up to and including 300mm2 4 core stranded copper conductors either i) paper insulated lead sheathed double steel tape armoured PVC oversheath cables, or ii) XLPE insulated, steel wire armoured, PVC over-sheathed cables. The cables will be terminated using heat shrinkable materials using compression lugs. The cable terminations material will be supplied by KAHRA MAA. Cable earth terminals will be terminated on the earth bar using suitable nuts and bolts. Cleats suitable for supporting and accommodating cables from 70 sq. mm to 300 sq. mm shall be fitted before delivery in addition to the Brass Wiping Glands. Brass Wiping Glands shall need to ensure that the bending moment coming through the Cable. Laying, shall not be transferred to connecting terminals. Bottom plate of the feeder pillar with cable entry holes, shall be divided into two portions. By removing the front portion, it shall be suitable to connect or disconnect any cable termination individually. The phase cable side fuse contacts (see Drawing EP-MS-P4/S2-010 Fig 2) shall be designed with long and short reach and shall be fitted with forward projecting M16 captive steel studs, one per contact complete with a full nut. A lock washer or plain washer and lock nut shall be provided. Bolts and studs shall be minimum ISO grade designation ISO 272, 885, 888/4759/1. The contacts shall be so designed that they provide adequate spacing and are fully interchangeable to permit terminating the phase conductors of a cable whatever their lay. There shall be no neutral link. The neutral conductor shall be terminated onto the contact bar rated at 250A mounted at the bottom of the units between the neutral busbar and the insulated support strut. The bottom fixing of the insulated support strut shall be mounted above the neutral contact bar so as to allow the neutral core an unimpeded approach to the desired fixing position. This neutral contact bar shall be drilled in two positions and fitted with a high tensile M16 steel bolt and nut. A lockwasher or plain washer and locknut shall be provided. Provision shall be made on each outgoing unit to affix and padlock a suitable insulated device to prevent fuselinks being inserted or removed. Two such devices shall be provided with each fuse cabinet. The devices shall not obstruct the fuse cabinet doors from closing when in position or when stored within the
EP-MS-P4/S2-010
fuse cabinet. It shall be possible to fit the device safely whilst the fuse cabinet is alive and in normal service. The device shall be marked with the following wording in English and Arabic in white letters on a red background, which shall be clearly visible when viewed from the front with the feeder pillar doors open : "CAUTION - MEN WORKING - DO NOT INTERFERE WITH THIS APPARATUS" Cable support shall be provided by a suitable cleat mounted at the bottom of the cabinet in such a manner that the cable entry to the cabinet is sealed by the cleat and that the cable is clear of any metalwork forming part of the base of the cabinet. The centre line of this cleat shall be not less than 460 mm below the centre line of the cable lug fixing of the neutral conductor. These cable supports shall be adequate to support the outgoing cable in normal service and when subjected to the short circuit duty specified in Section 6.0. There shall be one standard size of fixed contact assembly of one-piece construction which shall be suitable for accommodating a fuse carrier fitted with a 92 mm centre type 'J' fuse link in accordance with BS 88. Each fuse carrier shall be suitable for inserting in a phase of the unit by hinge action pivoted on the lower contact and for withdrawing by snatch action. The contacts shall be arranged to permit contact tightening and the contact surfaces shall be flat and accurately aligned in pairs. Fuse carriers shall be supplied with cabinets. Contact assemblies shall be supported from the steel framework by means of strips, rods, bars or mouldings of insulated materials; the arrangement of supports shall be such that mechanical stresses produced in service by the temperature rise of connections shall not adversely affect the alignment of the contact surfaces. It shall be possible with ease and safety when both busbar and outgoing circuits are live to fit a current transformer ratio 500/5, 5VA output Class D accuracy, of the design as supplied by the manufacturer over the red phase fuse contact of any outgoing unit, and to use a clip-on-ammeter over any fuse assembly when a current transformer is not fitted. Insulated dividing barriers shall be provided between phase contact assemblies and phase and neutral contact assemblies which shall make it impossible to insert a fuse link between contacts of different phases. If the dividing barriers are fastened to live metal, the resulting live bolts of fasteners shall not be exposed, without insulation on the lower side of the barrier 13.4 Busbars Busbars shall be of hard drawn high conductivity copper, of a size suitable for the rating of the fuse cabinet. The neutral bar shall be rated at not less than half of the rating of phase busbars.
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Busbar shall be situated at the rear of the equipment. Phase busbars shall be colour marked in sequence from top to bottom, red, yellow, blue, the neutral busbar, mounted below shall be colour marked black, and the earth busbar, mounted at the bottom shall be unmarked. The colouring of the busbars shall not be continuous and shall be such that it cannot be mistaken for an insulating covering. 13.5 Fuse Cabinets The shells of the fuse cabinets shall be weatherproof and of robust construction and shall be provided with a watershed tops. They shall be manufactured from sheet steel. Adequate ventilation shall be provided to permit natural circulation of air. The ventilation apertures shall be suitably screened to prevent entry of vermin and other foreign bodies. Degree of protection shall be IP41. The cabinet shall be designed to ensure that adequate clearance, not less than the clearance specified in Section 7.0 "Clearance", shall be provided to permit the incoming transformer circuit isolators to be left in an open or closed position and alive with the door closed and with the locking device in position. Provision shall be made for supporting the lower half of the cabinet by means of two adjustable supports, which shall bear against the tank of the transformer when the cabinet is in position. These supports shall be adjustable in length from inside the cabinet and shall have end caps to prevent damage to the transformer tank paint finish. Access to the front of the cabinet shall be via a door hinged on the left hand side viewed from the front, fitted with a locking bar to secure it top and bottom. The locking bar shall be operated by a central handle which shall be arranged to permit locking by a padlock with a 52 mm x 49 mm body and an 8.5mm diameter shackle having a clear inside width of 29mm and inside length of 41 mm to 55 mm. The holes provided for the shackle shall be not less than 10 mm diameter. For adequate illumination of cabinet, a heavy duty LED lamp with limit switch shall be provided inside the feeder pillar which interlocked with door open/close operation. All gaskets for doors shall be of superior quality and withstand the mentioned climatic conditions. The rear of the cabinet shall incorporate a short trunking piece of not less than 100 mm in length, which may be detachable. On all cabinets, this shall be centrally positioned in relation to the sidewalls of the cabinet. The thickness of the flange(s) of this trunking shall be strong enough to support the weight of the cabinet and cables and should be adequate to ensure a weatherproof seal when finally mounted onto the transformer and cabinet. The flange as shown in Drawing EP-MS-P4/S2-010 Fig. 3 shall be suitable for mounting on the transformer flange securing the low voltage bushing mounting plate on ground mounted and unit substation transformers to KAHRA MAA Specification. A gasket or gaskets of synthetic rubber bonded cork not less than
EP-MS-P4/S2-010
5 mm thickness shall be provided for insertion between the flange(s) of the cabinet and the transformer. Access shall be provided as requested by the Purchaser for earthing connections to be brought through the base of the cabinet. The cabinets shall be of the following maximum dimensions. External Width of Cabinet:Transformer unit Horizontal (mm) i) 4 outgoing ways 610 mm
From the horizontal centre line of the trunking: i) To the top of the cabinet ii) To the bottom of the cabinet 460 mm 1270 mm
All ferrous surfaces and edges shall be cleaned of scale and rust by shot blasting and shall then be treated on the same day, without outdoor exposure, with a zinc spray. The zinc shall be applied by a flame gun process of a thickness ZN4 in accordance with BS EN 22063:1994. This treatment shall be followed by the application of one coat of zinc chromate base priming paint, an undercoat and a final coat of durable oil and weather resisting paint. The final coat shall be Dark Admiralty Grey, colour 632 to BS 381C. All fuse cabinets shall be fitted with removable lifting devices mounted one at each end and as near as possible to the balance line. Any equipment, which is not stable on its own supports, shall be fitted for transit and storage with removable extension feet to provide stability. A data plate shall be fixed to the cabinet detailing the following information: i) Serial Number ii) Year of Manufacture iii) Normal current rating of busbar iv) Normal current rating of incoming unit v) Normal current rating of outgoing units. vi) Gross weight, when fully equipped (kg). vii) Manufacturers name and reference number. viii) Reference to KAHRAMAA Specification and contract/tender number. The gross weight shall also to be stenciled externally. 13.6 Accessories Fitted
13.6.1 Fuse Carriers A thorough grip shrouded fuse carrier of high quality non-inflammable and nonhygroscopic, DMC insulating material approved by Kahramaa shall be provided on each phase. Each carrier shall be complete with two insulated contact tightening thumbscrews. Reasonably good contact shall be made by wedge
EP-MS-P4/S2-010
action on inserting the fuse carrier so that current can be safely carried in the interval prior to the tightening of the contact tightening thumbscrews. Wedge action material shall be of brass and screws shall be of anti corrosive material. There shall be one standard size of fuse-carrier which shall carry a 92mm terminal centre fuse-link to type 'J' BS 88. Fuses for Distributor Circuits & Fuse Links will be supplied by the purchaser. 13.6.2 Fuses For Auxiliary Supply Fuse carriers for auxiliary circuits shall be of the withdraw-able handle insulated type with a rating of 60A and shall accommodate cylindrical cartridge type fuselinks of 32A with dimensions 57x22 mm, in accordance with type 11a fuses in BS 1361:1986. 13.6.3 Neutral and Earth Connections Separate neutral and earth bars shall be provided. They shall be solidly bolted together. The neutral bar shall be insulated from the shell, but the shell be bonded to the earth bar. A sideways projecting M 12 x 50mm captive stud complete with washer, nut, and lock nut connected to the earth bar shall project outwards from the shell. 13.6.4 Current Transformers The current transformers of ratio 800/5A, 1600/5A or 2400/5A as specified shall be provided on the incoming circuit of respective Feeder Pillars and securely fixed. The current transformers shall comply with the requirements of BS 7626 and IEC 60044 and shall be of 5VA output, Class 1 accuracy. They shall be suitable for the operation of thermal demand ammeters. The current transformers shall be of epoxy cast resin type capable of withstanding required temperature limits. The mounting of CTs shall be such that, in the event of failure, they shall be easily replaceable without the need for dismantling any major component. Only single ratio CTs are to be used. 13.6.5 Instrument Panels And Auxiliary Supply Circuits An instrument panel suitably wired shall be provided to accommodate three thermal demand ammeters (96x96mm size) with instantaneous pointer having a twenty-minute lag and with direct reading quadrant scales. The scales readings shall be in one side. Measuring ranges shall be 0-960A, 0-1960A and 0-2880A for C.T. ratios 800/5A, 1600/5A, and 2400/5A respectively. The cable connections shall be of sufficient length to allow for the removal of the indicators from the front panel. The following additional equipment shall be supplied:- 13A switched socket outlet to BS 1363. - 60A fuse base and carrier for socket, substation supplies and earth fault indicator reset supply. The instrument panel shall be mounted in such a position that neither cable installation nor jointing is impeded. Where it is mounted in front of the cables it shall be removable. The substation supplies circuit shall be wired to terminals on the side of the fusecabinet mounted below the level of the neutral bar. A 25 mm cable gland is to be equipped at right front corner of bottom plate, to terminate an outgoing 2 core 16mm PVC insulated steel wire armoured cable. It shall be possible to safely
EP-MS-P4/S2-010
connect the outgoing cable with the remainder of the pillar live in normal service. The terminal block shall be fully shrouded. 13.6.6 Small Wiring Small wiring shall be carried out in PVC insulated cable coloured black to BS 6231 Type B with 7/0.67 mm copper stranded conductors and with cores ferruled. The substation supplies circuit shall be wired to the terminal block with 16mm PVC insulated conductors having Red & Black colour insulation. The terminal block shall be identified with permanent labels. The secondary wiring of the group of current transformers shall be connected to earth at a single point on the terminal block, which shall be accessible from the front the pillar or fuse-cabinet. In addition to this, all secondary wires of CT are to be routed through TB. Wiring shall be fixed and where wiring cleats are used they shall be of the insulated limited compression type. Both the main connection from the phase bus-bar to the fuse and the main connection from the neutral bus-bar shall be hard drawn high conductivity copper not less than 75mm cross-section. If necessary use heat resistant grade wires for the small wiring to withstand the required temperature limits. 13.6.7 Circuit Labels & Permanent Wiring Diagrams A circuit label 75x50mm made of insulating material shall be mounted on the barrier between red and yellow phases of each circuit unit. This label shall be securely held without the use of screws or other metallic fixings and it shall be possible to slot into position and remove label from the front of the barrier. The labels shall be suitable for engraving black letters on a white background. The supports of the labels shall not be fixed to live parts. A permanent, indelible schematic & wiring diagrams, clearly indicating all terminal markings, components, shall be fixed inside the FP front door. 14.0 14.1 Tests Type tests The following type tests are to be conducted in reputed independent laboratory and copies of test reports shall need to be submitted.
a) b) c) d) e) f) g) h) i)
Verification of temperature rise limits (IEC 60439-5/8.2.1) Verification of Dielectric properties (IEC 60439-5/8.2.2) Verification of short circuit withstand strength (IEC 60439-5/8.2.3) Verification of clearances and creepage distances (IEC 60439-5/8.2.5) Verification of mechanical operation (IEC 60439-5/8.2.6) Verification of degree of protection (IEC 60439-5/8.2.7) Verification of mechanical strength (IEC 60439-5/8.2.101) Verification of resistance to abnormal heat and flame(IEC 60439-5/8.2.102) Verification of corrosion and aging resistance (IEC 60439-5/8.2.103)
14.2
Routine Tests Routine tests are to be carried out on every new assembly after it has been assembled at factory. One set of routine test reports of each FP shall be fixed
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inside the FP cabinet in a strong water-proof envelope. The following routine tests are to be carried out. a) Inspection of assembly, including wiring, healthy operation of instrument and electrical operation test(8.3.1) b) Dielectric test (IEC 60439-5/8.3.2) c) Electrical continuity (IEC 60 439-5/8.3.3) d) Insulation resistance (IEC 60439-5/8.3.4) 14.3 Tests on Painting The paint work shall need to pass following tests carried out during FAT and submit the report with each lot.
a) b) c) d) e)
Measurement of thickness of protective coating (ISO 2808) Cross cut test (ISO 2409): classification: 0 Cupping test (ISO 1520): 08mm Bending test Cylindrical mandrel test (ISO 1519): 3.0mm Salt spray (fog) test (ISO 7253): 1000hrs
15.0
WARRANTY, REPLACEMENTS & FAILURE ANALYSIS The manufacturer shall provide warranty for at least 3 years from the date of delivery, or 2 years from the date of installation, whichever is earlier, for each unit supplied, against any design, manufacture, and material defects. Any unit failed during service, with in the warranty period, need to be replaced with new unit. The faulty unit(s) needs to be fault-analyzed with reputed independent agencies and fault-analysis reports to be submitted. Further, it is the responsibility of the manufacturer to arrange for investigation of any abnormalities/defects observed during service period, even if it is out of warranty period.
16.0 RESTRICTIONS ON OUT-SOURCING 16.1 Out sourcing of any of main components related to Feeder Pillars, need to be declared in the beginning it- self, before the feeder pillars are pre-qualified or short listed for tenders. In such case, the manufacturer is responsible for quality of these main components and paint work, and need to produce all documentary evidences as to how they control quality of these components. 16.2 If any changes proposed by the manufacturer at later stage (after pre-qualification or short-listing in tenders) in sourcing of these main components or accessories, shall need to be informed to and obtain KM approval before the changes are made. Non-compliance of this condition may lead to rejection of goods.
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Specification for LV Distribution Fuse Board (Feeder Pillar

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Specification for LV Distribution Fuse Board (Feeder Pillar

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Specification for LV Distribution Fuse Board (Feeder Pillar)