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TECHNICAL SUBMISSION SECTION C- PART 2

PROJECT BRIEF PROJECT OVERVIEW, GENERAL REQUIREMENTS AND SPECIFICATIONS

SECTION 16345 3.3 KV METAL-CLAD SWITCHGEAR

PART 1 GENERAL

1.01 SCOPE OF WORK

A. Furnish and install the 3.3 kV metal-clad switchgear equipment as shown on the Drawings and as specified herein.

B. Install metering transformers that complies with KAHRAMAA.

C. Important data from the 3.3 KV switchgear panel shall be transferred to the local SCADA system for monitoring purposes (circuit breaker trips, alarms, earth leaks, etc.) as per Engineer’s approval.

1.02 RELATED WORK:

A. Power system studies are included in Section 16015.

B. Power distribution transformers are included in QCS 2014 Section 21, Part 31.

C. Diesel engine generator set is included in QCS 2014, Section 21, Part 17.

D. Concrete for equipment pad is included in other sections of QCS 2014.

E. Excavation is included in other sections of QCS 2014.

1.03 SUBMITTALS

A. Submit shop drawings and product data in accordance with QCS 2014, Section1, General, Part 7, Submittals.

B. Shop drawings shall include the following information:

1. Master drawing index

2. Front elevation view

3. Floor plan layout

4. Top view

5. Dimensions, weight, and shipping splits

6. Single line diagrams

7. 3-phase elementary and schematic diagrams

8. Nameplate schedules

9. Component list including metering, protective relays, accessories and control equipment

10. Conduit entry/exit locations

TECHNICAL SUBMISSION SECTION C- PART 2

PROJECT BRIEF PROJECT OVERVIEW, GENERAL REQUIREMENTS AND SPECIFICATIONS

11. Assembly ratings including:

a. Short-circuit rating

b. Voltage

c. Continuous current

d. Bus material and ratings

12. Major component ratings including:

a. Voltage

b. Continuous current

c. Interrupting ratings

d. Basic impulse level

13. Cable terminal lug sizes

14. Product data sheets and catalog numbers for circuit breakers and relays. List all options and accessories furnished specifically for this project.

C. Submit the following additional information where applicable:

1. Busway connection

2. Connection details between close-coupled assemblies

3. Composite floor plan of close-coupled assemblies

4. Key interlock scheme drawing and sequence of operations

D. Design Data:

1. Provide manufacturer's published time-current curves of the main breaker and feeder protective relay devices per Section 16015.

2. Submit battery sizing calculations showing required battery capacity for each battery set based on the criteria of, BS EN 60623 Recommended Practice for Sizing Nickel Cadmium sealed batteries for Generating Stations and Substations.

E. Test reports:

1. Submit type test reports for the proposed Equipment. Furnish documentation showing the results of design tests on a product of the same series and rating as that provided by this specification.

2. Submit production test reports showing results of testing performed on the actual equipment for this project. These tests include:

a. 50-hertz dielectric tests

b. Mechanical operation tests

c. Electrical operation and control wiring tests

d. Ground fault sensing equipment test.

3. Submit field test reports showing results of testing performed on the actual equipment for this project.

F. Submit manufacturer's installation instructions for the complete assembly and each major component:

1. Shipping, storage, and handling instructions

TECHNICAL SUBMISSION SECTION C- PART 2

PROJECT BRIEF PROJECT OVERVIEW, GENERAL REQUIREMENTS AND SPECIFICATIONS

2. Installation bulletins

3. Supplemental instruction bulletins.

4. Application software

5. Instructions necessary for proper seismic mounting of the equipment.

G. Statement of Qualifications:

1. When requested, submit qualifications of factory service representatives for

approval.

2. When requested, submit an acceptable list of installations with similar equipment to demonstrate compliance with this specification.

H. Manufacturer's Field Report:

1. When requested, submit manufacturers field inspection reports.

I. Project Record Documents:

1. Submit record document information in accordance with QCS requirements.

2. Submit the following information for record purposes:

a. A complete set of manufacturers "As Built" shop drawings incorporating all changes made during the manufacturing process.

b. "As Built" point-to-point compartment wiring diagrams for metering, relay and control circuits. Show wire and terminal numbers.

c. Field wiring interconnection drawings illustrating all field components and electric connections to the systems supplied under this Section.

d. Confirm and record all protective device settings.

3. Furnish electronic copies of switchgear drawings, one lines, and wiring diagrams in AutoCAD native file format. Drawings shall include any field modifications or changes to reflect actual as built conditions after completion of start-up and final acceptance by the Owner.

J. Operation and Maintenance Data:

1. Submit operation and maintenance manuals in accordance with QCS requirements.

2. Provide equipment operation and maintenance manuals with each shipped assembly including instruction leaflets, instruction bulletins and renewal parts lists for the complete assembly and each major component.

3. Manuals shall include the following as a minimum:

a. A comprehensive index.

b. A list of the equipment supplied, including serial numbers, ranges and pertinent

data.

c. Full product specifications for each item.

d. Service, maintenance and operation instructions for each item.

e. Special maintenance requirements particular to this system shall be clearly defined, along with set up and test procedures.

f. Renewal parts list with stock numbers.

TECHNICAL SUBMISSION SECTION C- PART 2

PROJECT BRIEF PROJECT OVERVIEW, GENERAL REQUIREMENTS AND SPECIFICATIONS

1.04 REFERENCE STANDARDS

A. International Electrotechnical Commission (IEC)

1. IEC 60298, high voltage switchgear in metallic enclosure

2. IEC 62271-200- Standards for high-voltage switchgear and control gear

3. IEC 60694 - Common Specifications For High-Voltage Switchgear and Control Gear Standards

4. IEC 62271-100- Standard for high-voltage switchgear and control gear

5. IEC 62271-101-Standard Test Procedure for AC High-Voltage Circuit Breakers Rated on a Symmetrical Current Basis

6. IEC 60298 Conformance Testing Procedure of Metal-Clad Switchgear

7. IEC 61869-1:2007 Requirements for Instrument Transformers

8. IEC 61643 - Surge protective devices connected to low-voltage power distribution systems

9. IEC 60364 Electrical installations of buildings

B. International Electrical Testing Association (NETA)

1. NETA ATS - Acceptance Testing Specifications.

C. British Standards (BS)

1. BS EN 62271-100:2001 - High-voltage switchgear and control gear. High-voltage alternating-current circuit-breakers

D. Ashghal, KAHRAMAA and QGEWC latest Specifications

E. Where reference is made to one of the above standards, the revision in effect at the time of the bid shall apply.

1.05 QUALITY ASSURANCE

A. Qualifications:

1. The equipment furnished under this Section shall be the product of a manufacturer who has produced this same type of equipment for a period of at least 10 consecutive years.

2. The switchgear equipment shall be designed, assembled and tested by the manufacturer of the major components and circuit protective devices used within the switchgear assembly.

3. Manufacturer shall maintain permanent records of each circuit breaker produced and the production test results.

4. The 3.3 kV Switchgear shall be manufactured by Siemens, ABB, ALSTOM, Schneider, Mitsubishi Electric in Europe or Japan only.

TECHNICAL SUBMISSION SECTION C- PART 2

PROJECT BRIEF PROJECT OVERVIEW, GENERAL REQUIREMENTS AND SPECIFICATIONS

B. Regulatory Requirements:

1. Equipment, materials, installation, and workmanship shall be in accordance with the mandatory and advisory provisions of NFPA 70 and QCS 2014 unless more stringent requirements are specified or indicated.

C. Certifications

1. The manufacturer shall maintain a documented ISO 9001 or 9002 quality assurance program implementing suitable procedures and controls to monitor all aspects of production and testing.

2. The switchgear shall be IEC type tested in a third party internationally recognized

laboratory as ASTA/KEMA, etc

documented as required by ISO 9001 and available for review and inspection.

Design tests, to verify IEC/BS ratings shall be

1.06 SYSTEM DESCRIPTION

A. General:

1. Furnish and install, where indicated, free-standing, dead-front type medium voltage metal-clad switchgear equipment, utilizing drawout vacuum type circuit breaker devices as specified herein and as shown on the Contract Drawings.

2. Modules and provisions shall include: circuit breaker compartments and circuit breakers, primary bus system, ground bus system, auxiliary compartments and transformers, protection and control devices, and connection provisions for primary, ground and control circuits.

3. Provide automatic source transfer controls as specified herein and as shown on the contract drawings.

4. Switchgear shall be coordinated with the engine generator set controls as specified QCS 2014, Section 21, Part 17 to make a complete and operational system.

B. System Responsibility:

1. Equipment specified under this Section shall be furnished as an integrated assembly by the manufacturer who shall have sole responsibility for furnishing all the parts and components required for a complete and operable system.

C. Design Requirements:

1. Voltage rating: designed for operation on a 3.3 kV, three phase, three wire, solidly grounded, 50 hertz system.

2. The entire switchgear assembly shall be rated to withstand mechanical forces exerted during short-circuit conditions when connected directly to a power source having available fault current of 350 MVA at rated voltage unless otherwise shown on the drawings.

3. The equipment and components shall operate continuously at its rated current under the specified environmental conditions without damage or degradation of operating characteristics or life:

TECHNICAL SUBMISSION SECTION C- PART 2

PROJECT BRIEF PROJECT OVERVIEW, GENERAL REQUIREMENTS AND SPECIFICATIONS

a. Operating Ambient Temperature: 0 degrees C to 50 degrees C maximum ambient temperature.

b. Storage Temperature: -30 degrees C to 65 degrees C.

c. Relative Humidity: 0 to 95%, non-condensing.

d. Altitude: Operating to 0 meter.

4. The bus shall be designed to carry its rated continuous current in the specified ambient temperature without exceeding the temperature rise limits specified in IEC Standard IEC 62271-200.

5. Equip useable blank spaces and spaces indicated for future devices with vertical bus, multi-ratio current transformers, metering and relaying as per one line diagram. The cubicle shall be equipped for a future breaker element.

6. Switchgear shall be capable of extension from either end at a future date without modification to existing structural members.

7. The manufacturer shall develop logic and interlocks and provide all programming as required to implement the protective relay philosophy, key interlocking schemes, metering and network communications as specified and indicated on the Contract

Drawings.

8. The manufacturer shall develop logic and interlocks and provide all programming as required to implement the breaker transfer schemes as specified and indicated on the Contract Drawings.

D. Performance Requirements:

1. Minimum short circuit interrupting rating: buses, bus supports and connections shall withstand stresses that would be produced by currents equal to the momentary ratings of the circuit breakers, and shall be braced to withstand fault currents equal to the close and latch rating of the breakers.

2. Main bus continuous current rating: 3000A. Line and load bus connections to circuit breakers shall be rated to carry the full continuous current of the device frame.

3. Power circuit breaker ratings: per IEC 62271-100.

a. Maximum Voltage: 5 kV

b. BIL Rated: 60 kV

c. Continuous Current: circuit breaker frame sizes shall be as shown on the Drawings.

d. Short-Circuit Current At Rated Maximum KV: 50 kA

e. Closing and Latching Capability: 135 kA rms

f. Short Time Rating: 50 kA

g. Rated Interrupting Time: 3 cycles

4. Control voltage: breakers shall be electrically operated by the following control voltages: 48 VDC close and trip.

5. The switchgear battery ampere hour rating shall be adequate to provide 3 consecutive circuit breaker Open/Close/Trip operations at the end of a 1 hour period, at a battery temperature of 45 degrees F. and minimum 8 hours discharge rate using manufacturer software to ensure proper discharge curve is used. Aging factor of 1.25 and design margin of 1.1 shall be clearly shown on the calculation. Charger sizing calculation shall be based on battery size with recharge time of 12

TECHNICAL SUBMISSION SECTION C- PART 2

PROJECT BRIEF PROJECT OVERVIEW, GENERAL REQUIREMENTS AND SPECIFICATIONS

hours assuming charger will support the continuous load as well as recharges the battery at the same time.

6. Surge Withstand Capability: per IEC 61000-4-5 without damage.

7. Metering accuracy: minimum accuracy of the complete system, including current sensors, auxiliary CTs, and the meter display, shall be +/- 1% of full scale for current values, and +/- 2% of full scale for power and energy values.

E. Power System Coordination and Protection

1. Provide a coordinated power system as specified in Section 16015

2. The switchgear manufacturer shall confirm all current and potential transformer

ratings.

F. Metering Requirements

1. Meter and display the following values at each breaker location:

a. AC Phase Amperes +/- 0.5%

b. AC Phase Voltage +/- 0.5%

c. Watts +/- 1.0%

d. VA +/- 1.0%

e. Vars +/- 1.0%

f. Power Factor +/- 2.0%

g. Frequency +/- 0.1 Hz

h. Watthours +/- 1.0%

i. Varhours +/- 1.0%

j. VA hours +/- 1.0%

k. Watt Demand (10-, 15-, 20-, 25-, 30-, 45-, 60-minute interval)

l. Voltage (minimum/maximum)

m. Current (minimum/maximum)

n. Power (minimum/maximum)

o. Power Factor (minimum/maximum)

p. Frequency (minimum/maximum)

q. Peak Demand

2. Power quality monitoring: display the following values at each main and feeder breaker location:

a. %THD (through 31st harmonic)

b. Peak % THD

1.07 AUTOMATIC TRANSFER CONTROL SYSTEM

A. Provide automatic source transfer controls as shown on the Drawings and as specified herein.

B. The transfer scheme shall include the following features and controls:

1. Drawout type voltage transformers with primary and secondary fuses on the line side of each incoming source.

2. AUTO MANUAL mode selector switch. In the MANUAL mode, automatic switching shall be inhibited and local electrical manual operation using the circuit breaker control switches shall be permitted.

TECHNICAL SUBMISSION SECTION C- PART 2

PROJECT BRIEF PROJECT OVERVIEW, GENERAL REQUIREMENTS AND SPECIFICATIONS

3. Three phase undervoltage, open/reverse phase and negative sequence voltage sensing relays or devices.

4. Electrical interlocks to prevent parallel connection of the two incoming sources.

5. A switch to permit either source to be selected as the preferred source.

6. A switch to permit either automatic or manual return to the preferred source.

7. Field adjustable 10 second time delay between transfer, either direction.

8. Source voltage available indicator lights, push to test, each source.

9. Manual retransfer pushbutton.

10. Provide a programmable logic controller with 24 volts dc ride-through power supply

11. Provide an industrial display panel

C. Dual Source, With Tie, Open Transition Automatic Transfer Control System

1. Where indicated on the drawings, provide an automatic transfer control system for control of ten circuit breakers. The logic of the transfer control system functions shall be provided via a microprocessor. The set points shall be field adjustable without the use of special tools

2. The transfer control system shall be provided with a local display. The display shall show the status of the system as it is operating. When timers are functioning, the display shall show the timer counting down. All time delays shall be capable of being set from the front of the display using a timer setting screen

3. The transfer control system includes the following features:

a. Time delay to transfer on loss of Source 1, adjustable.

b. Time delay to transfer on loss of Source 2, adjustable.

c. Time delay re-transfer to Source 1, adjustable.

d. Time delay re-transfer to Source 2, adjustable.

e. Time delay neutral (main and tie open), adjustable.

f. The local system display shall show the following: Main- Tie- Main one line diagram; main and tie breaker status (open, closed, tripped, out of cell); readout marked "Source 1" and "Source 2" to indicate that respective source voltages are available; automatic/manual mode select pushbutton; pushbuttons for manual breaker control; and alarm information (loss of source, breaker trip).

4. Sequence of Operation Automatic Mode

a. Under normal conditions, the 4 main breakers are closed, the 2 tie breakers are open, and the 4 generator breakers are open.

b. Safety interlocks shall prevent simultaneous connection of 2 separate sources on a common bus, in either auto or manual mode.

c. Upon phase loss or loss of phase-to-phase voltage of either KAHRAMAA

source to between 80% and 100% of nominal, and after a time delay, adjustable from 1 to 60 seconds to override momentary dips and outages the transfer control system shall open the affected main breakers and signal the respective 2 generators to start. The affected 1000kW pumps shall be prevented from running.

d. Once the generators have started, they shall complete a normal cycle.

TECHNICAL SUBMISSION SECTION C- PART 2

PROJECT BRIEF PROJECT OVERVIEW, GENERAL REQUIREMENTS AND SPECIFICATIONS

e. When the first generator has reached its rated voltage and frequency, the respective generator breaker shall close. The 2 nd generator shall parallel to the first generator.

f. When normal voltage has been restored after a time delay, adjustable from 10 to 600 seconds (to ensure the integrity of the source), the transfer control system shall open the generator breakers. The transfer control system shall have an adjustable neutral position timer (0-10 seconds) to allow voltage to decay sufficiently before the affected main breakers are then closed (open transition retransfer).

g. If the generator should fail while carrying the load, transfer to KAHRAMAA shall be made instantaneously upon restoration of service to satisfactory conditions.

h. If both generator and KAHRAMAA sources should fail simultaneously, no action shall be taken.

i. If the main or generator breakers trip due to a fault, the transfer control system shall be reset to manual mode and manual operation of that breaker shall be prevented until its overcurrent trip switch is reset.

j. The switchgear shall also be capable of remote monitoring and control from the pumps station.

k. In manual mode, all breakers shall be capable of being opened and closed using control switches and push buttons, including the tie circuit breaker. Safety interlocks shall not be overridden in manual mode.

1.08 DELIVERY, STORAGE AND HANDLING

A. Packing and Shipping

1. Equipment shall be handled and stored in accordance with manufacturer's

instructions.

2. Shipping groups shall be designed to be shipped by truck. Indoor groups shall be bolted to skids. Breakers and accessories shall be packaged and shipped

separately.

B. Acceptance at Site

1. Switchgear shall be equipped to be handled by crane. Where cranes are not available, switchgear shall be suitable for skidding in place on rollers using jacks to raise and lower the groups.

C. Storage and Protection

1. Refer to QCS 2014, Section 21, Part 01.

1.09 PROJECT/SITE REQUIREMENTS

A. Environmental Requirements

1. All printed circuit boards shall be conformally coated to provide environmental

robustness.

B. Existing Conditions

1. The equipment will be installed in an air conditioned room, as shown on Drawings.

C. Field Measurements

TECHNICAL SUBMISSION SECTION C- PART 2

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1. Make all necessary field measurements to verify that equipment will fit in allocated space in full compliance with minimum required clearances specified in National Electrical Code.

1.10

MAINTENANCE

A. Maintenance Service

1. Service-inspection during the first year of operation at Owner's request exclusive of repair, malfunction, or other trouble-shooting service calls. One 8-hour days.

B. Provide the following materials in the quantity specified. Materials shall match those installed in all respects and where possible shall come from the same production lot. Materials shall be properly packaged for long storage and containers shall be clearly and indelibly labeled on the exterior.

1. One quart of touch-up paint.

2. One dozen each of cover bolts, spring nuts and door fasteners.

C. Spare Parts

1. Provide the following spare parts in the quantities specified:

a. One set of three fuses of each type of fuse supplied with the switchgear for

each set of five installed.

b. One set of three contactor vacuum bottles for each size of medium voltage vacuum contactor supplied.

c. One solid state protective relay for each type supplied.

d. One control relay for each type of relay supplied.

e. Three Pilot lamps of each type.

2. Spare parts shall be boxed or packaged for long term storage and clearly identified on the exterior of package. Identify each item with manufacturers name, description and part number.

D. Tools

1. Provide a portable lift truck for lifting, handling and transporting a breaker outside its

compartment.

2. Manual racking handle.

3. An electrical test cabinet with door-mounted open and close pushbuttons shall be supplied for bench testing electrically operated circuit breakers away from the

switchgear.

4. A remote racking device shall be provided including push-button, motor operator, and 25 feet of cable.

5. Manufacturer's standard, manually operated, Ground & Test device shall be supplied for main bus and system grounding during maintenance.

6. The battery shall be supplied complete with intercell and intertray connecting conductors and end terminals. The following maintenance accessories shall be provided:

TECHNICAL SUBMISSION SECTION C- PART 2

PROJECT BRIEF PROJECT OVERVIEW, GENERAL REQUIREMENTS AND SPECIFICATIONS

a. A set of socket wrenches and other necessary tools.

b. A set of cell numerals.

c. Appropriate mechanical lifting and handling devices for batteries.

7. Provide a hand-held programming unit to set/change the network communication address for each microprocessor-based device, set the system baud rate, distribution frequency, display status information, and display monitored values. Require password protection for programming time/current set points and to perform functional testing of phase and ground trip characteristics. The programmer shall be self-powered by an internal battery. Provide as a minimum one hand-held programming unit.

1.11 WARRANTY

A. The equipment shall be warranted for 5 years from the date of commissioning to be free from defects in workmanship, design or material. If the equipment should fail during the warranty period due to a defective part, it shall be replaced and the unit restored to service at no additional cost to the Owner.

1.12 NOMENCLATURE AND IDENTIFICATION

A. Provide engraved laminated plastic nameplates on all doors for unit load description and for each control or indicating device. Nomenclature shall be as shown on the Drawing or as directed, using lettering approximately 9.5 mm high for unit identification nameplates and 6.35 mm high elsewhere. The nameplates shall use [black letters on a white background] [white letters on a black background]. The engraving shall extend through the black exterior lamination to the core. Nameplates shall be screw fastened.

B. The manufacturer shall fasten a master IEC nameplate to the front of the switchgear indicating model number, serial number, order number, manufacturing date, bus amperes, volts, overall short circuit rating, etc.

C. Each circuit breaker shall be identified with an individual serial number permanently mounted on the breaker by means of a metal nameplate.

D. Provide permanent electrical hazard warning signs marked per OSHA requirements.

E. Provide permanent arc flash PPE signs marked per Section [16015] requirements.

1.13 MANUFACTURERS' SERVICES

A. Provide services of a manufacturer's service representative for testing and start-up, as required in QCS and as follows: two days, two trips.

B. Provide services of a manufacturer's service representative for training, as required in in QCS and as follows: two days, two trips.

C. Furnish the services of a manufacturer's representative for a minimum period of three eight-hour days for setup and programming of the power management system and metering devices. The manufacturer's representative shall be factory-trained and shall have a thorough knowledge of the software, hardware, and system programming.

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PART 2 PRODUCTS

2.01 GENERAL

A. The use of a manufacturer's name and model or catalog number is for the purpose of establishing the standard of quality and general configuration desired.

B. Product manufacturers shall be according to QCS 2014 standards Section 21 Part 32 and QGEWC, applicable to all related manufacturers.

C. Like items of materials/equipment shall be the end products of one manufacturer in order to provide standardization for appearance, operation, maintenance, spare parts, and manufacturer's service.

2.02 MATERIALS:

A. Wiring

1. Low voltage instrument and control wiring: UL/CSA approved stranded copper, minimum size 2.5Sq.mm, with 600 Volt, 90 degree C, flame retardant, Type SIS. Current transformer circuits shall utilize minimum size. 6 Sq. mm wire.

2. Low level signal and communication circuit wiring: twisted shielded pair cables to minimize electromagnetic interference. Shielded wire grounded at one point.

3. Physical protection: Enclose control wiring in a grounded metal raceway when routed through a high voltage compartment. Exposed wiring shall be neatly bundled and secured with nylon wire ties and protected against contact with sharp metal edges by protective grommets. Control wiring passing from cubicle to door shall be spiral wrapped to prevent damage.

4. Control circuit protective devices: dead-front pullout fuse blocks shall be used for circuit protection and disconnect. Charge circuits and close and trip circuits shall be separately fused.

5. Control wiring terminations: provide insulated locking spade terminals, except where saddle type terminals are provided integral to a device. Current transformer secondary leads shall first be connected to conveniently accessible shorting type terminal blocks before connecting to any other device. [Provide current and voltage test plugs for field monitoring and maintenance.]

6. Terminal blocks: Groups of control wires leaving the switchgear shall be provided with terminal blocks with numbering strips. Provide a minimum of 10% spare terminals on each terminal block.

7. Wiring identification: provide molded plastic clip-sleeve or heat shrinkable type wire markers at each termination point, marked with identification corresponding to appropriate designations on manufacturer's wiring diagrams, color coding per QCS 2014 standards and IEC.

8. Component identification: fuse blocks, relays, pushbuttons, switches, etc., shall be marked with identification corresponding to appropriate designations on manufacturer's wiring diagrams.

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9. Power cable terminations: two hole IEC 60529 & BS 2613 bus pads with provisions for attaching clamp compression/crimp type cable terminals suitable for copper cable of the number and sizes shown on the Drawings. Provide adequate vertical clearance for electric stress cone cable terminations.

10. Grounding lugs: provided in the incoming line section for connection of the main conductor with additional lugs for supplemental grounding conductors as indicated on the drawings.

B. Buses

1. Main and riser bus: tin-plated copper with a flame retardant, track resistant fluidized bed epoxy insulation system. Bus joints shall be plated, bolted and insulated with removable PVC boots.

2. The main and vertical riser busses shall be enclosed in a segregated metal compartment with removable covers for accessibility. The main bus pass through insulators and main bus standoff insulator supports shall be molded of cycloaliphatic epoxy. The bus supports between units shall be flame-retardant, track-resistant, glass polyester for 27 kV class.

3. Circuit breaker load side runbacks shall be copper bus with epoxy insulation and porcelain support bushings. Circuit breaker primary connections shall be mounted in insulated contact tube assemblies, bolted to the rear of each breaker cell compartment.

4. For rigidity during fault conditions, all connections to roll-out potential transformer trays and control power transformer trays shall be rigid bus bars insulated to the full voltage rating of the switchgear assembly.

C. Grounding

1. Ground bus: provide a plated copper ground bus extending throughout the entire length of the switchgear, firmly secured to each vertical section structure and equipped with lugs for external ground connections, sized for cables shown on the Drawings.

2. Make provisions for connection of incoming and outgoing cable sheaths and for the copper grounding conductors shown on the Drawings.

3. Provide a ground bus riser assembly in each cable compartment connected to the ground bar in each circuit breaker or potential transformer drawout assembly compartment. Connect metering, relaying and instrument transformer grounds to this riser assembly.

4. Provide a grounding disconnecting device between each circuit breaker removable element and the equipment ground bus which shall maintain contact at all times, except when the primary disconnecting devices are separated at a safe distance.

5. Provide a static grounding device on each voltage transformer drawout carriage to contact the primary fuses in the disconnected position. Each drawout carriage shall be bonded to the ground riser bus assembly.

D. Potential Transformers

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1. Potential transformers: Two-winding, encapsulated drawout type with primary and secondary fuses. Voltage ratings and accuracy shall be as required for the application in accordance with IEC 61869-1.Voltage transformers shall have 110 volt secondary unless otherwise specified and a burden capacity equal to twice the initial load.

2. Voltage transformers shall be designed to withstand the basic impulse level of the switchgear. Current limiting fuse protection shall be provided on the primary side of each voltage transformer.

3. Where physical size restrictions do not allow the voltage transformer to be mounted in a drawout assembly, the voltage transformer may be stationary mounted with the fuses only mounted in the drawout unit. The appropriate interlocks shall be provided to insure maximum operator safety.

4. When moved to the withdrawn position, the transformer drawout unit shall automatically ground the transformer primary windings and the fuses. A visible indication of positive ground is required. The ground may be a momentary or sweeping action that occurs as the unit moved out of the connected position.

E. Current Transformers

1. Current transformers: Auxiliary ring core type current transformer (CT) shall be located behind the shutters. They shall be bushing-mounted and accessible from the front. Bushings shall accommodate up to four standard accuracy CTs per phase for all ratings.

2. Current transformers shall be fully rated for the appropriate voltage class. Each current transformer shall be rated to withstand the thermal and mechanical stresses imposed by the short circuit rating of the applied circuit breaker.

3. CT ratings and accuracy shall be in accordance with IEC 61869-1:2007 and IEC 60298 .The CT winding shall terminate in a screw type terminal on the CT housing and shall be wired to shorting terminal blocks. Current transformers shall have 5 ampere rated secondary current unless otherwise specified.

F. Pilot Devices

1. Circuit breaker control switches: 600 Volt switchgear rotary cam type, with engraved face plates, rated 20 Amps continuous, momentary contact, spring return type having mechanical target or flag and a fixed, pistol grip handle.

2. Indicator lights: Provide green, red and amber pilot lights for each circuit breaker OPEN, CLOSED and TRIP indication.

3. Ammeter and voltmeter transfer switches shall have an off position and shall be provided with knurled knob handles.

4. Selector type control switches (Auto-Manual or Hand-Off-Auto) shall have oval handles.

G. Surge Arresters

1. Provide station class surge arresters in each incoming circuit section.

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PROJECT BRIEF PROJECT OVERVIEW, GENERAL REQUIREMENTS AND SPECIFICATIONS

2. Provide surge suppressors on each outgoing circuit using a vacuum circuit breaker.

2.03

EQUIPMENT

A. Switchgear shall consist of the required number of vertical sections bolted together to form a rigid framework of preformed steel channels or angles covered with bolted steel sheets. Each individual breaker/metering cell shall be completely segregated from adjacent compartments and sections by steel barriers at top, bottom, rear and sides. All edges of front covers or hinged front panels shall be formed. Provide adequate ventilation within the enclosure.

B. All sections of the switchgear shall be front and rear aligned with depth as shown on Drawings. Devices shall be front removable and load connections front and rear accessible. Rear access shall be provided.

C. Rear cable compartments: isolated from the main and riser bus by insulated or grounded steel barriers with cable supports in each vertical section. Cable compartments shall be of sufficient depth to accommodate the number and size conduits shown on the drawings, with bending space in accordance with the IEC.

D. Enclosure

1. IP54 Enclosure consisting of side, top and rear covers bolted to steel frame structure members. Front doors shall be hinged and gasketed with captive quarter turn fasteners.

E. Customer Metering

1. Where indicated on the drawings, provide a separate customer metering

compartment with a front facing hinged door and include the following:

a. Current transformers for each meter. Current transformers shall be wired to

shorting-type terminal blocks.

b. Potential transformers including primary and secondary fuses with disconnecting means for metering as shown on the drawings.

F. Drawout cells: equip breaker cells with drawout rails and primary and secondary disconnecting contacts, and safety interlocks.

1. Power disconnecting means: moving finger contacts on the power circuit breaker studs to engage stationary contacts extending through a glass polyester insulating support barrier only in the connected position. Provide multiple silver-to-silver full floating high-pressure point contacts with uniform pressure on each finger maintained by springs. A metal or lexan shutter shall automatically cover the stationary primary disconnecting contacts when the breaker is in the disconnected position or out of the cell.

2. Secondary control power disconnecting means: plated pin and socket type plug-in connectors mounted on the removable unit and engaging floating plug-in connectors at the front of the compartment.

3. Racking mechanism: Each breaker shall have a self-contained racking mechanism to move the breaker between the TEST/DISCONNECT and CONNECTED positions and to align and secure the primary disconnects in the CONNECTED position. Circuit breakers shall be capable of being racked in or out with the compartment door closed.

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4. Position indicator: color-coded visual indication of the breaker cell position.

5. Interlocks: provide interlocks to prevent the following operations:

a. Racking a closed breaker into or out of the CONNECTED position with the door in the open position.

b. Opening the compartment door unless the circuit breaker is in the disconnected position and safety shutters are closed. This interlock shall also include an indication of shutter position on the front of the compartment door.

c. Withdrawing a circuit breaker from the cubicle while the closing springs are charged.

d. Insertion of a circuit breaker of incorrect frame size or inadequate interrupting capacity.

e. Interlocks shall be provided to prevent closing of a breaker between CONNECTED and TEST/DISCONNECT positions, to trip breakers upon insertion or removal from housing and to discharge stored energy mechanisms upon insertion or removal from the housing. The breaker shall be secured positively in the housing between and including the CONNECTED and TEST/DISCONNECT positions.

6. Removable element (TOC) auxiliary switch contacts: provide 6 normally open and 6 normally closed, break-before-make auxiliary contacts wired to terminal blocks to indicate breaker position in the cell.

2.04 POWER CIRCUIT BREAKERS

A. Power circuit breakers: removable, electrically operated, vacuum interrupter type with stored energy trip/close mechanism, mounted in a heavy gauge steel frame with a removable front panel cover. The following mechanical indicators and devices shall be visible and accessible through the front cover:

1. Open/close indicator

2. Operations counter

3. Spring charge indicator

4. Manual charging arm

5. Racking screw

B. Each circuit breaker shall contain three vacuum interrupters separately mounted in a self-contained, self-aligning pole unit, which can be removed easily. The vacuum interrupter pole unit shall be mounted on glass polyester supports for 27 kV class.

C. Contact wear gap indicator: indicate available contact life for each vacuum interrupter. Indicator shall be easily visible when the breaker is removed from its compartment. The breaker front panel shall be removable when the breaker is withdrawn for ease of inspection and maintenance.

D. Secondary contacts: silver-plated contacts that automatically engage in the breaker operating position, and can be manually engaged in the breaker test position.

E. Circuit breaker position: provide 6 spare "a" and 6 spare "b" mechanism operated (MOC) auxiliary switch contacts wired to terminal blocks for remote status indication of breaker open/close condition.

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F. Each breaker shall be complete with control switch and red and green indicating lights to indicate breaker contact position.

2.05 AUXILIARY CONTROL POWER

A. DC Control Power

1. Each breaker shall be electrically operated from a station battery. Breaker operating mechanism shall be electrically charged, stored energy type. Charging motor shall include a limit switch feature and an anti-pump relay. Make provisions for manual charging of the mechanism and for slow closing of the contacts for inspection and

adjustment.

2. Control power shall be provided from interconnected Nickel-Cadmium (NiCd) type battery cells as shown in QCS 2014 Section 21 part 27, Chloride or equal. Batteries shall have at least a 15 year pro rated warranty and a one year full guarantee.

3. Cell containers shall be translucent, shock absorbing, heat resistant plastic, with electrolyte level marks and spray proof, flame arresting type vents. Battery shall be furnished with all connectors and hardware, lifting device, electrolyte, terminal plates, cables, grease and connectors.

4. A floor mounted structural steel battery rack shall be furnished specifically designed for battery service. The rack shall be finished with an acid and fire resistant epoxy coating and non-metallic rail covers.

5. Battery charger shall be a fully automatic, filtered, float type charger suitable for wall or rack mounting. Input voltage shall be 240VAC, single phase, 50 Hz. The DC output shall be regulated to within 0.5 percent regardless of fluctuations of the input voltage and shall be current limited at 120 percent of rated output. Accessories shall include DC ammeter and voltmeter (panel type; 2 percent accuracy), adjustable float and equalize controls and toggle switch, AC and DC circuit breakers, AC power failure alarm relay, low DC voltage alarm relay and DC ground fault relay. The charger shall be C&D Power System, ARR Series; Chloride, Model SCR F, or equal.

6. Provide the following circuits with individual indicating lights:

a. Low DC voltage alarm

b. High DC voltage alarm

c. No current alarm

d. Ground detection

e. Provide a AC power failure alarm circuit.

7. Provide a Form C contacts for monitoring of minimum battery voltage and other critical alarms to SCADA monitoring system

2.06 METERING AND CONTROL

A. Digital Metering

1. Type: CE certified microprocessor based, solid state, door mounted digital line meter device with accuracy per IEC 62056-1-0:2014.

2. Surge withstand rating: meet IEC 61000-4-5 for surge withstand.

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3. Inputs: Provide external voltage and current transformers with rating as indicated on the drawings. Control power shall be supplied internally from the switchgear.

4. Operator interface: faceplate shall be membrane type, rated IP 54, with a durable backlit display to allow simultaneous viewing of multiple parameters. The meter shall be completely programmable using the display keypad or via network communications to allow the user to disable undesired values/functions and to later reactivate them if required. The display screen shall indicate trip and alarm conditions.

5. Non-volatile memory: All set points and recorded minimum and maximums shall be stored in non-volatile memory and not require battery backup. In the event of a power failure, the meter shall retain all preset parameters, accumulated watthours and watt demand. Data at time of power loss and cause of trip shall be stored.

6. Synchronous pulse input: when activated shall override the preset watt demand interval and let the KAHRAMAA control the demand window.

7. Onboard input and outputs: provide separate programmable contacts. The contacts shall have ratings of 10 Amps at 110/240 VAC and shall be NO/NC.

8. kWh pulse output: provide a separate field programmable NO/NC contact for a kilowatt hour pulse.

9. Operating temperature range: 0 to 70 degrees C, and 0 to 95 percent relative humidity non-condensing.

10. Reset function: a built in reset button shall allow manual reset of a trip or alarm condition. Watt-hours and watt demand shall be resettable.

2.07 PROTECTIVE RELAYS

A.

General

1. The switchgear manufacturer shall furnish and install in the metal-clad switchgear the quantity, type and rating of protection relays as indicated on the Drawings and described hereafter in this specification. Unless otherwise approved, protective relays shall be KAHRAMAA grade, manufactured as per QCS 2014 Standards.

2. Microprocessor based multi-function solid state relays shall be provided. Single function relays may be used for specific applications to supplement the features of the multi-function relays. Protective relays shall be drawout type with removable dust tight viewing covers, front accessible connection plugs, built-in test capability, and external reset.

3. Relays shall operate from the 5-ampere secondary output of current transformers.

4. Relay components shall have a conformal coating for harsh environments. Conformal coating material shall be applied in an even layer across the printed circuit board (PCB) providing a thickness no more than 4 mils and no less than 1 mil. Coating shall be applied to all areas of the PCB with the exception of grounding connections, cable connections, and areas of the PCB not used for electrical tracing or tracing insulated by PCB solder resist. Coating application shall be applied by spray application, not by dipping the PCB in the coating material.

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5. The primary current transformer rating being used for phase and ground protection feeding the device shall be programmable for current transformers with primary current ratings from 5 through 5,000 amperes.

6. Relays shall have true RMS sensing of each phase and ground. Ground elements shall be capable of being utilized in residual, zero sequence, ground source connection schemes, or deactivated.

7. Current and potential test blocks and plugs shall be provided for all metering and protection circuits.

8. Relays shall provide access to data via a front-panel LCD display and the serial ports. Relays shall be capable of displaying custom programmable messages.

9. Relays shall include extensive self-testing and an alarm output contact indication of self-test warning or failure conditions or removal of dc power.

10. Relays shall be configured by Microsoft® Windows®-based graphical software and ASCII terminal interfaces.

B. Each incoming Main Breaker shall be provided with a Multilin SR-750, Schweitzer SEL 351S or Basler BE1-951, drawout, KAHRAMAA grade, multi-function protective relay. Provide the following minimum protective functions for each Main Breaker:

1. Instantaneous/Time Overcurrent (50/51) function, 3-phase, percent adjustable, utilizing IEC trip curves.

2. Under/Over Voltage (27/59) function, 3-phase, percent adjustable, percent reset, with time delay.

3. Over/Under Frequency (81 O/U) function, single phase, percent adjustable, percent reset, with time delay.

4. Phase Sequence/Phase Failure (47) function, 3-phase, percent adjustable, with time delay

5. Reverse Power (32) function, 3-phase, percent adjustable with time delay.

6. Directional Instantaneous/Time Overcurrent (67) function, 3-phase and directional ground overcurrent (67N/67G) with time delay.

7. Lock-out (86) relay, manual reset

C. Each non-paralleling Tie Circuit Breaker shall be provided with a Multilin MIF II, Schweitzer SEL 551 or Basler BE1-851, drawout, KAHRAMAA grade, multi-function protective relay. Provide the following minimum protective functions for each non- paralleling Tie Circuit Breaker:

1. Instantaneous/Time Overcurrent (50/51) function, 3-phase, percent adjustable, utilizing IEC trip curves.

2. Lock-out (86) relay, manual reset.

3. Instantaneous/Time Overcurrent (50/51) function, 3-phase, percent adjustable, utilizing ANSI trip curves.

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4. Lock-out (86) relay, manual reset.

D. Provide a Schweitzer SEL-487B two zone bus differential scheme (87B/87G) with separate differential current transformers for all incoming and outgoing loads, as well as appropriate differential relays.

E. Each incoming Generator Circuit Breaker shall be provided with a Multilin SR-489, Schweitzer SEL 300G or Basler BE1-CDS220. Provide the following minimum protective functions for each Generator:

1. Instantaneous/Time Overcurrent (50/51) function, 3-phase, percent adjustable, utilizing IEC trip curves.

2. Under/Over Voltage (27/59) function, 3-phase, percent adjustable, percent reset, with time delay.

3. Over/Under Frequency (81 O/U) function, single phase, percent adjustable, percent reset, with time delay.

4. Reverse Power (32) function, 3-phase, percent adjustable with time delay.

5. Loss of Field (Reverse VAR, 40) function, 3-phase, percent adjustable with time delay.

6. Differential Phase Fault (87G) function, 3-phase, percent adjustable with time delay.

7. Microprocessor Engine Governor Load Sharing and Soft Loading Control (65).

8. Automatic Synchronizer (15/25), adjustable sync window and sync window dwell time.

9. Manual Paralleling Synch Check (25).

10. Var/Power Factor Controller (90 PF).

2.08 NETWORK COMMUNICATIONS

A. Provide interface hardware, cabling, and software to enable the following microprocessor-based devices to communicate with the plant-wide network:

1. Metering devices

2. Protective relays

3. Automatic transfer controller

B. Communicate metering and relay device data to a plant-wide power management network.

C. Communications gateway: Provide a distributed data logging gateway, interface hardware, cabling, and software to connect local microprocessor-based devices to a plant-wide fiber optic communications network.

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2.09 SURFACE PREPARATIONS AND SHOP COATINGS

A. All exterior and interior steel surfaces of the switchgear shall be properly cleaned and provided with a rust-inhibiting phosphatized coating. Color and finish of the switchgear shall be in accordance with manufacturer’s recommendations and with BS 6150 and BS EN ISO 12944.

B. Outdoor equipment shall be painted with two finish coats of polyurethane or epoxy enamel, 1 to 2 mm thickness. Exterior color shall be manufacturers standard gray.

C. Unpainted non-current carrying parts shall be galvanized to prevent corrosion.

2.10 SHOP TESTING

A. Perform manufacturers standard production testing and inspection in accordance with IEC 60298 (62271-200) and IEC 56 (62271-100)standards., including:

1. Check component bill of material for proper quantity, description, and part number.

2. Check physical dimensions against approved drawings.

3. Perform primary current injection tests to determine proper operation of all current sensitive components.

4. Perform primary voltage injection tests to determine proper operation of all voltage sensitive components.

5. Perform a low frequency withstand (AC high potential) test performed on the complete assembly to assure insulation system integrity.

6. Mechanical operation tests to include interlocks, drawout element operation, shutter operation, etc.

7. Electrical operation and control wiring tests including correctness of wiring and insulation tests, polarity, verification and sequence tests.

8. Instruments, meters, protective devices and associated controls shall be functionally tested by applying the specified control signals, current and/or voltages.

9. Effectiveness of grounding of instrument transformer case or frame grounding

10. Medium Voltage breakers shall be tested and inspected as follows:

a. Alignment of all mating and matching points including drawout mechanism, bushing matching, auxiliary contact mating, and grounding shoe contact to assure correct operation and interchangeability of breaker units.

b. Each circuit breaker shall be tested for proper adjustment and operation prior to shipment. The circuit breaker shall be given a minimum of 100 mechanical operations.

c. Each vacuum interrupter shall receive a vacuum integrity test by means of the system ac high potential test prior to shipment.

d. Each circuit breaker shall have contact timing and motion velocity tests.

B. All equipment shall be type tested in a third party internationally recognized laboratory as ASTA/KEMA, etc. IEC type test reports shall be provided for Engineer’s approval.

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C. FAT shall be witnessed by the Contractor in the presence of Supervisory consultant and specialist Client representative. FAT test procedure shall be submitted by the contractor and approved by the Engineer 45 days in advance of FAT witness test.

PART 3 EXECUTION

3.01 GENERAL

A. Install the switchgear as shown on the Drawings and in accordance with IEC 62271-200, the manufacturer's instructions, and approved shop drawings.

3.02 FIELD CONNECTIONS

A. Provide driven ground rods as specified in QCS. Connect ground conductors to the upper end of the ground rods by exothermic weld or compression connector. Provide compression connectors at equipment ground bus.

B. Provide bare copper cable not smaller than 120 sq mm not less than 600 mm below grade connecting to the grounding electrode system.

C. Make wiring interconnections between shipping splits.

D. Install bus splice plates and torque the connections.

E. Install medium voltage cables per QCS. Bond cable sheaths to the switchgear ground bus.

F. Field low voltage wiring shall be grouped by circuit and tie wrapped. Terminations shall not be stressed.

G. Insulate the primary cable connections to bus pads and lightning and surge arrestors. Fill voids around bolted connections with 3M Brand SCOTCHFIL electrical putty and apply tape insulation or heat shrink insulating boots in accordance with the switchgear manufacturer's installation instructions.

3.03 INSTALLATION

A. Remove temporary lifting angles, lugs and shipping braces. Remove all current transformer shunts after completing secondary circuits.

B. The equipment shall be leveled and anchored directly to a concrete equipment pad or finished floor as shown on the Drawings. Provide hardware and metal shims for installation. Grout and caulk all voids beneath the equipment base. Anchor bolts shall be [16 mm galvanized steel, minimum.

C. The assembly shall be bolted directly to floor sills set level in concrete per manufacturer's recommendations. Floor sills are not required if the floor is level to 3 mm per 1 meter distance in any direction. Provide all necessary hardware to secure the assembly in place.

D. Locate conduit and cable entrances in the space designated by the equipment manufacturer. Install conduits to prevent water from entering the enclosure. Bond all conduits including stubs to the equipment ground bus. Seal voids around conduit openings in the slab with water- and oil-resistant caulking or sealant. Cut off and bush conduits three inches above slab surface.

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E. Where field painting of enclosures is required to correct damage to the manufacturer's factory applied coatings, provide manufacturer's recommended coatings and apply in accordance with manufacturer's instructions.

F. Repair damage to galvanized coatings using zinc rich paint.

3.04 FIELD TESTING

A. Perform physical, electrical, and mechanical inspections in accordance with the manufacturer's recommendations and the following. Provide all temporary power for testing.

1. Compare equipment nameplate data with specifications and approved shop drawings.

2. Inspect physical, electrical, and mechanical condition.

3. Verify appropriate anchorage, required area clearances, and correct alignment.

4. Inspect all doors, panels, and sections for paint, dents, scratches, fit, and missing hardware.

5. Verify that current transformer ratios and polarity correspond to approved shop drawings.

6. Confirm correct operation and sequencing of electrical and mechanical interlock systems.

7. Inspect insulating materials and structure for evidence of physical damage, reduced clearances, or contaminated surfaces.

8. Verify that field wiring is adequately separated from live busses. Physically secure the field wiring to withstand the effects of fault currents.

9. Check all devices for damage and make all necessary repairs or replacements, prior to energizing.

10. Verify correct barrier and shutter installation and operation.

11. Exercise all active components.

12. Inspect all mechanical indicating devices for correct operation.

13. Verify that vents are clear.

14. Test operation, alignment, and penetration of disconnecting contacts.

15. Inspect control power transformers.

16. Verify all ground connections have been made.

17. Verify operation of space heaters.

18. Verify that all maintenance devices such as special tools and gauges specified by the manufacturer are available for servicing and operating the breaker.

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19. Verify the unit is clean.

20. Perform all mechanical operation tests on the operating mechanism in accordance with manufacturer's published data.

21. Measure critical distances such as contact gap as recommended by manufacturer.

22. Inspect bolted electrical connections for high resistance using one of the following methods:

a. Use of low-resistance ohmmeter.

b. Verify tightness of accessible bolted electrical connections by calibrated torque- wrench method in accordance with manufacturer's published data.

c. Perform thermographic survey.

23. Verify cell fit and element alignment.

24. Verify racking mechanism operation.

25. Verify appropriate lubrication on moving current-carrying parts and on moving and sliding surfaces.

26. Record as-found and as-left operation counter readings.

B. Perform electrical acceptance tests on the switchgear in accordance with NETA ATS and IEC 62271-200, including;

1. Conduct an electrical insulation resistance test to verify that the equipment and field wiring are free from short circuits and grounds. Test phase-to-ground, phase-to- phase, and phase-to-neutral, with the circuit breakers opened.

2. Overpotential tests.

3. Insulation-resistance test on control wiring; do not perform this test on wiring connected to solid-state components.

4. Control wiring performance test.

5. Primary current injection tests on the entire current circuit in each section of

assembly.

6. Phasing check on double-ended switchgear to ensure correct bus phasing from each source.

7. Conduct earth resistance ground testing.

8. Insulation power factor and resistance test for surge arresters.

C. Perform the electrical acceptance tests on circuit breakers and protective relays in accordance with NETA ATS and IEC 62271-200, including;

1. Contact resistance tests.

2. Insulation resistance tests.

3. Perform minimum pickup voltage tests on trip and close coils in accordance with manufacturer's published data.

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4. Trip circuit breaker by operation of each protective device. Reset all trip logs and indicators.

5. Perform vacuum bottle integrity (dielectric withstand voltage) test across each vacuum bottle with the breaker in the open position in strict accordance with manufacturer's published data.

6. Perform power-factor or dissipation-factor tests.

7. Test instrument transformers.

8. Perform diagnostic testing on protective relays.

D. Perform the following before energizing the equipment:

1. Retighten all accessible electrical connections to the manufacturer's torque values.

2. Place all circuit breakers in the OPEN position before energizing the bus.

3. Adjust ground overcurrent protective devices to their most sensitive settings during start-up. Reset the devices after startup is complete and the equipment has been successfully energized.

4. Reinstall all parts and barriers removed to facilitate wiring and installation.

5. Before closing the enclosure, remove all metal chips, scrap wire, and other debris from the switchgear interior. Remove accumulated dust and dirt by using a brush, vacuum cleaner or clean, lint-free rags.

6. Install covers, close doors, and make certain that no wires are pinched and that all enclosure parts are properly aligned and tightened.

E. Performance Test.

1. Verify complete system operation including all hardware, software and communication devices.

2. Verify networking performance with all interfacing systems by other manufacturers.

3.05

ADJUSTMENT

A. Perform field adjustments and programming of the protective devices as required to place the equipment in final operating condition. The settings shall be in accordance with the approved short circuit and protective device coordination study.

B. Provide the following services for starting up and programming of the power management system and metering devices:

1. Set all the adjustable or programmable parameters of all devices in the equipment.

2. Coordinate startup with other manufacturersequipment.

3. Verify the integrity of the data communications network and troubleshoot as necessary.

4. Set all the network addresses of all devices in the equipment.

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3.06

CLEANING

A. Remove all rubbish and debris around the switchgear. Remove dirt, dust, and concrete spatter from the exterior of the equipment using brushes, vacuum cleaner, or clean, lint free rags.

END OF SECTION

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SECTION 16481 MEDIUM VOLTAGE MOTOR CONTROL CENTER

PART 1 GENERAL

1.01 SCOPE OF WORK

A. Furnish and install the 3.3 kV group mounted motor control center as shown on the Drawings and as specified herein.

1.02 RELATED WORK

A. Motors are included in Division 11.

B. Concrete for equipment pad is included in QCS 2014, Section 5.

1.03 SUBMITTALS

A. Submit, in accordance with QCS 2014, Section 01, Part 07, shop drawings and product data, for the following:

1. Itemized bill of material.

2. Descriptive information (weight, length, height, etc.).

3. Dimensional outline drawings.

4. Elevation drawings identifying each compartment.

5. Conduit entrance locations.

6. Bus arrangement, material, ratings and insulation details.

7. Protective Devices: Copies of time-current characteristics and instructions.

8. Operational description.

9. Anchoring instructions and details.

10. Typed tabulation:

a. Motor name; equipment tag numbers as shown on Drawings.

b. Motor horsepower.

c. Nameplate full load current.

d. Measured load current and voltage.

e. Protective device trip settings.

11. Point-to-point wiring diagrams for metering, relay and control circuits. Show wire and terminal numbers. Diagrams shall include:

a. Remote control devices.

b. Remote indication and/or pilot lights.

c. Interconnections and interlocking circuits between starter and remote equipment.

d. Remote sensors.

e. Tag numbers associated with all control devices and equipment.

12. Three-line diagrams.

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13. Product data sheets and ratings for interrupter switches, starter assemblies, and power fuses. List all options and accessories furnished specifically for this project.

14. Product data sheets for metering, protective relays, accessories and control equipment.

15. Certified shop test reports.

16. Field test and inspection reports.

17. Instruction and renewal parts books.

1.04 REFERENCE STANDARDS

A. The medium voltage motor controllers and protection devices in this specification shall be designed and manufactured according to latest revision of the following standards unless otherwise noted:

1. IEC 60546 Controllers with analogue signals for use in industrial-process control systems IEC 61140 Protection against electric shock Common aspects for installation and equipment IEC 60529 - Degrees of protection provided by enclosures IEC 60529

2. IEC 60255 - Electrical Relays IEC 62271-103 Medium-Voltage Switchgear and Control gear

3. IEC 62053-21 Electricity metering equipment (a.c.).

4. IEC 60060-1 Medium-Voltage test techniques

5. IEC 60331 - Tests for Electric Cables under Fire Conditions

B. Solid-state circuitry shall meet or exceed the Transient Overvoltage Withstand Test per IEC 600060-1 and the Surge Withstand Capability Tests (SWC) per -IEC 60099-6. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply.

1.05 QUALITY ASSURANCE

A. The equipment furnished under this Section shall be the product of a manufacturer who has produced this same type of equipment for a period of at least 10 consecutive years.

B. Equipment shall be designed, assembled and tested by the manufacturer of the components used in the motor control center to assure a completely coordinated design and establish a single source of responsibility for the equipment's performance.

C. 3.3 KV MCC’s shall be manufactured by Siemens, ABB, ALSTOM, Schneider, Mitsubishi Electric in Europe or Japan only.

1.06 PRODUCTS SHALL BE TYPE TESTED IN AN INTERNATIONALLY RECOGNIZED THIRD PARTY LABORATORY.DELIVERY, STORAGE AND HANDLING

A. Shipping Splits: Established by Contractor to facilitate ingress of equipment to final installation location within the building.

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B. Store, protect, and handle products in accordance with recommended practices listed in manufacturer's Installation and Maintenance Manuals

C. Deliver each shipping split mounted on shipping skids and wrapped for protection.

D. Inspect and report concealed damage to carrier within specified time.

E. Store motor control center in a clean, dry space. Maintain factory protection or cover with heavy canvas or plastic to keep out dirt, water, construction debris, and traffic. Heat the enclosures to prevent condensation.

F. Handle motor control center in accordance with manufacturer's written instructions to avoid damaging equipment, installed devices, and finish. Lift only by installed lifting eyes.

1.07 [PROJECT/SITE REQUIREMENTS]

1.08 MAINTENANCE

A. Furnish the following maintenance accessories.

1. One fuse handling tool

2. One set of three 3 meter grounding jumpers and storage bags.

3. One audio-visual voltage tester with batteries, storage case and clamp stick adapter.

4. One clamp stick with canvas storage bag.

B. Provide the following spare parts specified:

1. One dozen each of cover bolts, nuts and special hardware.

2. One refinishing kit for field touch-up of paint.

3. Three replacement power fuses or refills for each starter and switch.

4. One arc chute assembly.

5. One interrupter switch blade assembly.

6. Two switch insulators and connector links.

7. Two replacement fuses for voltage transformers.

8. One spare 1000 kW reduced voltage solid state starter.

C. Spare parts shall be boxed or packaged for long term storage and clearly on the exterior of the package. Identify each item with manufacturers name, description and part number.

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1.09 WARRANTY

A. All equipment and components furnished under this section will be warranted in accordance with QCS requirements and the General Conditions for a period of 5 years from the date of commissioning.

PART 2 PRODUCTS

2.01 RATINGS

A. Distribution system configuration: 3 Phase, 50 Hz, solid grounded wye.

B. The motor control center assembly shall have the following ratings. The fault ratings of switches, bus, motor controllers, and fuses shall equal or exceed the specified short circuit rating of the motor control center.

1. Nominal system voltage: 3.3 kV

2. Maximum design voltage:

5 kV

3. Impulse level (BIL):

60 kV

4. Short circuit rating:

360 MVA.

C. The continuous current rating of the bus shall be 3000 Amps. The bus shall be designed to carry its rated continuous current in the specified ambient temperature. The bus supports, bus and interconnections shall equal or exceed the specified equipment maximum short circuit rating.

D. The equipment shall be designed for continuous operation at its rated current in a 50 degree C ambient temperature.

2.02 CONSTRUCTION

A. General

1. The general arrangement of the motor control center is shown on the Drawings. Motor control center shall be as manufactured by approved manufacturers as per KAHRAMA and ASHGAL Standards.

2. Each motor controller, switch and fuse assembly, and auxiliary unit shall be mounted in an individual, free standing, self-supporting, metal enclosed cubicle constructed of sheet steel. Cubicles shall be bolted together to form a group lineup with full steel barriers between adjacent cubicles.

3. Each cubicle shall be provided with a full height, hinged front door equipped with rotary latches with padlockable handles. Interlocks shall be furnished to prevent operation of the isolating mechanism under load; operating of the medium voltage compartment before the controller is isolated and closing the line contactor, while the door is opened.

4. The enclosure shall be braced and vented to prevent distortion under fault conditions up to the specified short circuit rating.

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5. Indoor structures shall be constructed of steel channels, angles, and sheets, bolted or welded together. Make provisions for top or bottom cable entrance as shown on the Drawings. Structures shall be front accessible only.

B. Auxiliary Sections

C. Buses and Insulators

1. Group lineups shall be interconnected by a horizontal, high-conductivity silver plated copper bus system. Bus connections shall be made with high strength, high conductivity bolts and locking hardware.

2. Busses, switches and fuse assemblies shall be mounted on porcelain insulators conforming to IEC 60233 Tests on Hollow Insulators for use in Electrical Equipment.

3. Incoming main and bus tie switch cubicles shall be isolated from adjacent cubicles by means of fully rated, non-tracking, self-scouring porcelain through-bushings in the main bus. Through-bushings shall be provided between each bay in outdoor equipment lineups.

4. Bus bars and joints shall be insulated where IEC standard clearances cannot be maintained.

D. Grounding

1. Make provisions for connection of incoming and outgoing cable sheaths and for the copper grounding conductors shown on the Drawings.

2. Group lineups shall have a continuous ground bus extending through the entire length of the of the motor control center. Bus material and short circuit rating shall be equal to the main bus. The ground bus shall have at least one bolted connection to the structure in each bay.

E. Control and Secondary Wiring

1. Wiring: 650 Volt, stranded copper, Type SIS, flameproof switchboard wire, minimum size 2.5 Sq.mm for control, 4Sq.mm for power and instrument transformer secondaries.

2. Identification and termination: Ring type, crimp on wire lugs with sleeve type wire markers at each termination point. Terminal blocks shall be 20 Amp, 650 Volt, screw type with white marking area. Provide shorting type terminal blocks for current transformer secondary wiring.

F. Marking and Identification

1. Unit nameplates: Provide black phenolic, white core, 1-in by 3-in nominal, engraved nameplates with customer unit designation, fastened to each door with stainless steel screws, or rivets.

2. Rating nameplates: Provide permanent, stamped or engraved metal rating nameplates indicating manufacturers name, model number, order number, voltage, current and interrupting ratings for bus, switches and power fuses.

3. Warning signs: Provide permanent warning signs as follows:

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a. "Caution-High Voltage-Keep Out" on all external doors and removable cable compartment panels.

b. "Danger-High Voltage-Qualified Persons Only" on internal doors.

4. QCS 2014 requirements for marking and identification.

2.03 MOTOR CONTROLLERS

A. Motor Controllers

1. Type: IP 54, gasketed, one-high. Motor starter type shall be drawout vacuum break Full Voltage Non-Reversing (FVNR).

2. For personnel safety, enclosure(s) shall have: low-voltage control compartment with separate door; medium voltage compartment with separate interlocked door; ac bus compartment with protective barriers; and cable entrance compartment.

3. Cable Entrance: Motor leads enter from bottom; control and circuits enter from

bottom.

4. Controller shall be fused type with current-limiting power fuses that provide an interrupting rating as specified. Starter shall use 400-ampere vacuum contactor. Contactor shall have fixed mounted connections. Coil shall be removable without removing contactor from its mounts. Vacuum interrupter wear checks shall not require removal of contactor.

5. Controller shall be isolated by a non-load-break quick-make quick-break isolation switch operated by an externally mounted handle. Isolation switch shall open control power transformer secondary before opening main circuit. Mechanical interlocks shall be provided to prevent:

a. Inadvertent operation of isolation switch under load;

b. Opening medium voltage compartment door when isolation switch is ON.

c. Closing isolation switch with medium voltage compartment door open;

d. Operating contactor with isolation switch in intermediate position;

e. Closing line contactor with door open.

6. Controllers shall be rated 60 KV Basic Impulse Level (BIL). Control power transformer and may be rated 25 KV BIL.

B. Controls

1. Disconnecting Device: Capable of de-energizing external source control circuits in

unit.

2. Control Devices: As indicated and as specified in QCS 2014, Section 21, Part 03.

3. Control power at 110 volts shall be provided from a control power transformer in each controller. Transformer shall be protected by current-limiting fuses.

4. Each motor controller shall be protected against single-phasing due to blown fuses and shall have blown fuse indication. Blown fuse indicator shall be mounted on controller door.

5. Controls shall provide instantaneous under-voltage protection when momentary contact push-button is used.

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6. The following control devices shall be mounted on the front panel:

a. Start pushbutton, black.

b. Stop pushbutton, red.

c. Local-Off-Remote selector switch.

d. Running pilot light, red.

e. Off pilot light, green.

f. Overload Alarm pilot light, amber.

g. Overload Tripped pilot light, amber.

C. The motor protection relay shall be mounted on the control panel front.

D. Controller shall include 110 VAC test power when isolating switch is in open position.

1. Test circuit shall consist of receptacle and plug mounted in low voltage compartment and accessible only when low voltage door is open.

2. In test position, plug may be removed from receptacle and connected to external 110VAC source of power.

3. This shall isolate control transformer and prevent energizing control transformer secondary from test voltage source.

E. Identify devices mounted in low voltage compartment.

F. Motor heater control: provide the control circuitry for a motor space heater. The heater shall be interlocked with the starter run relay and shall be energized when the starter is off. Provide a white, door mounted Motor Heater On pilot light. The 240V AC power shall be provided from an external source, thus allowing the motor heater to be energized even while starter power is removed.

2.04 REDUCED VOLTAGE SOLID STATE STARTERS

A. Provide medium voltage combination solid state starters as specified herein. The solid state starters shall be microprocessor controlled suitable for use with three phase induction motors. It shall provide a closed loop current ramp for smooth and stepless motor acceleration and deceleration.

B. Control Configuration

1. The solid state starter shall be supplied standard with dip switches or else with programming buttons on one main keypad with LCD display.

2. Standard starter control logic shall be located on a microprocessor-based PC card which provides the sequential logic for the starter and gate signals to the power card and then to the pulse cards which are used to drive the SCRs.

3. Design control logic to perform timing required for operation of the solid state starter, inline contactor and bypass contactor while continuously monitoring motor and starter for faults. If a fault is detected, the control logic of the solid state starter shall provide fault indication via an LCD display. In the event of a fault condition, the control logic shall safely shut down the starter to disable the motor.

4. The PC cards of the solid state starter shall be interchangeable with other control logic cards on starters of a similar design.

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C. Low Voltage Compartment

1. Locate low voltage section behind separate door and physically separated from medium voltage section by an insulated lexan mounting chassis which allows only visual access to medium voltage section.

2. Door to permit access to control logic without exposure to medium voltages.

3. Customer interlocking and control are interfaced in this section as well as metering, relays, and pilot devices.

4. Optically- isolate main control PC card located in low voltage section from medium voltage pulse generator cards on power poles.

D. Electrical

1. The logic control of the solid state starter shall incorporate a micro-computer which consists of all circuitry required to drive the power semiconductors and provide motor and starter monitoring functions.

2. The solid state starter logic shall provide the following standard features:

a. Adjustable Ramp Time (0 to 30 seconds Accel, 0 to 120 seconds Decel)

b. Adjustable Initial Current (50 to 400 percent of motor FLA)

c. Adjustable Max Current (200 to 500 percent of motor FLA)

d. Adjustable Decel Profile for Pumps

e. Adjustable Motor Full Load Amperes

f. Battery "Backup" of Set Starter Parameters, unless use dip switches

g. Kick Start

E. LED Indicators

1. The following LED indicators or LCD display shall be provided for advisory status and fault annunciation:

a. Power On

b. Starting

c. Running

d. Energy Saver

e. Stopping

f. Fault

g. Start Fault

h. Stalled Motor

i. Temperature Fault

j. Line Fault

2.05 POWER FACTOR CORRECTION CAPACITORS

A. Power Factor Correction Capacitors shall be supplied with the medium voltage starters. They shall be located in an enclosure within the starter lineup, completely factory wired.

1. Capacitors shall be mounted in indoor dustproof enclosures.

2. Capacitors and discharge resistors shall be non-toxic liquid insulated and hermetically sealed in steel enclosures.

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3. Discharge resistors shall reduce voltage to 50 Volts or less within 5 minutes of de-

energization.

4. Each capacitor unit shall be furnished with 50,000 ampere high interrupting capacity current limiting fuses. Fuses shall be equipped with "blown-fuse" indicators.

5. Capacitors shall be type HWT as manufactured by approved manufactures of KAHRAMAA and ASHGHAL Standards.

2.06 MOTOR PROTECTION RELAY

A. The digital motor protection relay shall incorporate the following functions and features.

1. Protective Functions

a.

Overload

b.

Stall

1)

The digital motor protection relay shall use voltage compensation of the

2)

stall / acceleration curve for additional protection. A speed switch input shall be available.

c.

Jam

d.

Negative sequence unbalance / single phase

e.

12 RTD inputs

f.

Ground overcurrent (Provide zero sequence current transformer for sensitive detection of ground faults on a high resistance grounded system).

g.

Short circuit

h.

i.

Stator thermal protection model shall combine inputs from positive and negative sequence currents and RTD winding feedback for provides dynamic following of motor loading and temperature rise.

2. Additional functions provided from voltage transformer inputs shall be:

a. Overvoltage

b. Under-voltage

c. Voltage phase reversal

d. Over frequency

e. Under-frequency

3. The digital motor protection relay shall include a complete onboard power metering package, including:

a. Amps, Volts, Watts, Vars, Volt Amperes, Power Factor and Hz.

b. Watthour and Varhour

c. Demand: Amp, Watt, Var, Volt Ampere peak

d. Temperature (rtds)

e. Analog inputs

B. User Interface

1. The digital relay shall have the following user interfaces:

a. Integrated keypad to access actual values and setpoints. 2-line, 40 character

vacuum fluorescent display for use with keypad. The relay shall have:

1)

Variable scrolling rates.

2)

Front mounted LEDs to display alarms, trips and relay status.

3)

Relay reset button and LED to indicate when the relay may be reset.

2. Communications with the digital relay shall be accomplished by:

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a. RS485 communications port.

b. Open protocol with user selected baud rates to 19.2 K.

c. An independent RS485 port shall be furnished for system security and maintenance.

d. Setpoint programming shall be available through a front mounted RS232 interface.

3. The relay shall have discrete inputs and a 4-20 mA analog output.

4. Relay output shall be through alarm and trip functions.

5. Relay shall provide time and date of alarm and trips.

6. Relay memory shall store the last 50 events.

C. Provide one software kit for setting parameters. Interface software shall be in a Microsoft Windows format.

2.07 LOAD BREAK AIR INTERRUPTER SWITCHES

A. Load Break Interrupter Switches

1. Load interrupter switches: 3 Pole, two position, gang operated, bottom hinged stationary load break type, mounted on a rigid, welded steel frame. Main switch blades shall be high conductivity, hard drawn copper. Mechanical linkages shall be porcelain or epoxy, with leakage and flashover distances equal to the mounting insulators. Circuit interrupting arc shall be completely contained and vented within the arc chutes. Impact resistant viewing windows shall be provided for visual inspection of switch position. Fuse holders shall be furnished on the inside of each switch compartment and voltage transformer cubicle door. Provide full depth barriers between each switch and power fuse assembly

2. Manual switch operator: Quick make, quick break, non-defeatable, high speed, stored energy operating mechanism actuated by a non-removable, external operating handle, capable of being padlocked in either the OPEN or CLOSED position. Opening and closing shall be accomplished by a single upward or downward stroke of the handle. The operating speed of the interrupter switch shall be independent of the operator handle speed. Provide permanent "OPEN-CLOSED" switch position indicator targets.

3. Provide full depth interphase and side barriers of insulating material in switch and fuse compartments.

4. Provide an expanded metal screen door barrier in front of the switch compartment, independent of the cubicle door.

5. Key interlocks: Provide Kirk or Superior mechanical key interlocks to prevent switch operations as shown on the Drawings.

B. The continuous and load break interrupting capacity of each switch shall be 600 Amps. Duty cycle fault closing rating shall be 40,000 Amps, RMS, asym.

C. Power Fuses

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1. Power fuses: Self-contained, current limiting type designed to provide fault interruption with minimum let-through current and with no expulsion of gases or vapor. Fuses shall be Westinghouse Type CX, CXN, CLE, or equal.

2. Continuous current ratings shall be as shown on the Drawings. Time-current characteristics shall be determined by the Engineer during shop drawing review, based on the recommendations made in the Coordination Study provided under Section 16015.

3. Cable terminations; Two-hole IP bus pads with provisions for attaching compression/crimp type cable terminals suitable for copper cable of the number and sizes shown on the Drawings. Provide adequate vertical clearance for electric stress cone cable terminations.

D. Electric Switch Operators

1. Electric switch operators: Where shown on the Drawings, provide stored energy type operators equipped with an electric charging motor or close and trip solenoid. Motor shall charge the operating mechanism within 4 seconds after each switch operation. Provide a torque limiter when necessary to prevent damage to the charging mechanism. Switch operators shall include the following features.

a. Removable manual charging handle.

b. Local electric OPEN and CLOSE pushbuttons.

c. Local mechanical OPEN and CLOSE trip operators.

d. Switch position target indicators OPEN/CLOSED.

e. Charging mechanism target indicators CHARGED/DISCHARGED.

f. Non-resettable operations counter.

g. Four pole double throw auxiliary switch contacts.

E. Instrumentation and Metering

1. Indicating meters: 4-in square, 250-degree scale switchboard type with a full scale accuracy of plus or minus 1 percent. Types as shown on the Drawings.

2. Instrument and control switches: 50 Volt switchboard type, rated 20 Amps continuous, with black molded phenolic escutcheon plates, white characters.

3. Voltage and control transformers: Two winding, encapsulated, [stationary] [drawout] type with current limiting primary fuses. Voltage ratings shall be as required for the application or as shown on the Drawings. Short circuit and BIL ratings shall be equal to the equipment rating.

4. Current transformers: Mount and wire bar type CT's, quantity and ratio as shown on the Drawings with relay and metering accuracies per ANSI standards. BIL rating shall be equal to the equipment rating.

F. Lightning and Surge Protection

1. Surge arresters: Provide a set of three Distribution Class, metal oxide type lightning surge arrestors at each location shown on the Drawings.

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2.08 SURFACE PREPARATION AND SHOP COATINGS

A. All non-current carrying metal parts of the equipment shall be cleaned of all weld spatter and other foreign material and given a hot iron-phosphate chemical treatment. A zinc rich, heat cured, epoxy primer shall be applied to inhibit rust.

B. Indoor equipment shall be finish painted with one coat of manufacturers standard air dried enamel.

C. Unpainted steel parts shall receive a protective zinc plating to prevent corrosion. Printed circuit boards shall be coated with a protective conformal epoxy. All control device contacts shall be silver plated.

2.09 SHOP TESTING

A. Equipment shall be type tested in a third party internationally recognized laboratory as ASTA/KEMA, etc. Type test reports as per IEC standard shall be provided for Engineer’s approval.

B. Contractor shall submit valid Type test reports as per current IEC/BS standard during Tender period and MAS approval for the proposed equipment.

C. The BIL rating of the integrated motor control center assembly shall be established by test on equipment of the type and kind to be furnished under this Section. Submit certified copies of these test reports, if requested by the Engineer.

PART 3 EXECUTION

3.01 INSTALLATION

A. The equipment shall be mounted on U type channel frame embedded in the concrete floor at the same level with the room floor level, for assurance of proper leveling. Install the equipment in accordance with the manufacturer's instructions.

B. Remove temporary lifting angles, lugs and shipping braces. Touch-up damaged paint finishes.

C. Make wiring interconnections between shipping splits.

D. Install bus splice plates and torque the connections.

E. Caulk seams, cracks and openings in outdoor enclosures.

3.02 FIELD TESTING

A. Engage the services of a recognized independent testing firm to inspect and test the installed equipment prior to energization. The testing firm shall provide all material, labor, equipment and technical supervision to perform the tests and inspection. Notify the Engineer at least 2 weeks prior to scheduling any testing.

B. Equipment testing and inspection shall be performed in accordance with NETA Standard ATS and shall include the following.

1. Visual and mechanical inspection.

2. Ratio and polarity tests on current and voltage transformers.

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3. Ground resistance test.

4. Insulation resistance tests (bus and switches)

5. Over potential test (bus and switches)

6. Meter calibration.

7. Air switch contact resistance test.

8. Insulation power factor and resistance test for surge arresters.

C. In the event of an equipment fault, notify the Engineer immediately. After the cause of the fault has been identified and corrected, a joint inspection of the equipment shall be conducted by the Contractor, the Engineer and the equipment manufacturer's factory service technician. Repair or replace the equipment as directed by the Engineer prior to placing the equipment back into service.

3.03

CLEANING

A. Remove all rubbish and debris from inside and around the equipment. Remove dirt, dust, or concrete spatter from the interior and exterior of the equipment using brushes, vacuum cleaner, or clean, lint-free rags. Do not use compressed air.

END OF SECTION