Spec Ac.doc

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DOCUMENT TITLE

NISCO 230/33 KV SUBSTATION ECHNICAL SPECIFICATION for AC EQUIPMENT

C:\Documents and Settings\All Users\Documents\sub-2-9-88\88.8.30\SPEC AC\spec ac.doc

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DOCUMENT TYPE : Spec. DOCUMENT TITLE :

230/33 KV SUBSTATION TECHNICAL SPECIFICATION for AC EQUIPMENT

2

1

Rev.

NOV. 09

AUG. 09

DATE

A.Alizadeh

M.Khosravian

A.Hemmatian

Issued For Approval

A.Alizadeh

M.Khosravian

A.Hemmatian

Issued For Review

Prepared Checked CONTRACTOR

Approved

Client

Purpose of Issue

This document and the information disclosed are the property of MMTE and are not to be used to furnish any information for making of documents or apparatus except where approved by written agreement.

Confidential: This document discloses proprietary information. It may not be reproduced nor disclosed any person, nor used for any purpose, except with the written .permission of MMTE

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REVISION RECORD SHEET

Note: This Table is used for External Comments

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AC EQUIPMENT

1 1.0 GENERAL……………………………………………………………………………… …….4 2.0 DESCRIPTION…………………………………………………………………………….....6 3.0 TERMINOLOGY…………………………………………………………………………...…6 4.0 STANDARDS…………………………………………………………………………..…….6 5.0 DESIGN AND CONSTRUCTION…………………………………………………..…..…..6 6.0 SPARE PART ………………………………………………………………………........…15 7.0 SUBMITTALS ………………………………..…………………………………………..…15 8.0 INSPECTION AND TESTS………………………………………..………………………16 9.0 SUPERVISION OVER INSTALLATION AND ERECTION ……………………………17 10.0 MEASUREMENT AND PAYMENT……………………………………………………..18

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:Project Document NO

AC EQUIPMENT

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This Specification Describes the Minimum requirements for design, inspection and testing of AC EQUIPMENT of MIYANEH STEEL MAKING PLANT (MIYANEH SMP). 1.2

LANGUAGE

All correspondence and submittals shall be in English. 1.3

DOCUMENT PRIORITY

In the event of any conflict between these specifications, the requisition, drawings, codes and standards, the priority shall be given in the following order. a. Purchase order b. Drawings c. This specification d. Codes and standards In any case vendor shall refer the matter with Purchaser and obtain clarification before proceeding with any work. 1.4 SITE LOCATION Site selected for MIYANEH SMP is located northwest of IRAN, at East AZERBAYJAN Province - Longitude :

47° 42’ E

- Latitude :

37° 27’ N

- Elevation :

app. 1110 m above sea level

1.5 METEOROLOGICAL CONDITIONS. The steel making plant to be designed and based on the following site data: 1.5.1 Ambient temperature - Registered temperature Confidential: This document discloses proprietary information. It may not be reproduced nor disclosed any person, nor used for any purpose, except with the written .permission of MMTE

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AC EQUIPMENT

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Page: 5 of 18

Highest recorded:

+41.8°C

Lowest recorded:

-25.6°C

Average recorded:

+14.3°C

- Design conditions Max. Ambient temperature:

+20°C

Min. Ambient temperature:

+6.9°C

1.5.2. Relative humidity Relative humidity :

max. %71 min. %35

1.5.3. Rainfall Yearly rainfall :

Ave. 274.6 mm

Max. Monthly rainfall :

46.1 mm

1.5.4. Atmospheric pressure Average :

0.89 bar

Basic wind speed for design

80 km/h.

- Pollution degree : 1.5.5. Earthquake

heavy pollution degree because of steel making

1

Earthquake load will be in accordance with the Iranian code of practice for Seismic Resistant design of Building, standard 2800 (latest edition). For this project following factor .shall be applied Seismic zone: Region 2 (High Seismic Zone) Design base acceleration: 0.3 G Soil: type II

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NISCO 230/33 KV SUBSTATION ECHNICAL SPECIFICATION for AC EQUIPMENT

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2.0 DESCRIPTION Station service systems mainly shall mean 33/0.4KV auxiliary transformers, AC distribution panels, battery chargers, battery and battery racks, D.C. distribution panels, standby diesel generator and accessories.Work of this document includes design, manufacture , factory testing , transportation and supervision over installation and erection of the station AC system(AC distribution panels & standby diesel generator and accessories). The extent of work shall include the following: (1) 380/220 volt A.C. main and distribution panels for both indoor and outdoor A.C. services. (2) standby diesel generator and accessories 3.0 TERMINOLOGY Technical terminology is to be as defined in latest edition of IEC 50 and I.E.E.E 100 standards. 4.0 STANDARDS Work of this Chapter shall comply with the requirements of latest edition of IEC, BS, DIN, ANSI and NEMA standards within which IEC standard is preferred. Metric SI system of units shall be applied to all dimensions and relevant documents.

5.0 DESIGN 5.1 A.C. Distribution Panel boards 5.1.1 General The main A.C. distribution panel boards shall be three phase and contain molded case Confidential: This document discloses proprietary information. It may not be reproduced nor disclosed any person, nor used for any purpose, except with the written .permission of MMTE

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circuit breakers to feed the switchyard lighting panel board , building lighting , heating and C:\Documents and Settings\All Users\Documents\sub-2-9-88\88.8.30\SPEC AC\spec ac.doc

cooling panel boards , A.C. power supply to the battery chargers and relay and control panels in the control and switchgear buildings , and all other equipment requiring A.C. power . In addition , the main panel board shall contain breakers for the main incoming station service supplies with suitable automatic changeover . A minimum of 20% spare breakers shall be provided . The minimum number and rating of the A.C. C.B’s shall be in accordance with the relevant drawings . Photocell and contactor and necessary accessories for automatic control of the switchyard lighting should be provided . Panels shall be dead front type with modular steel enclosures and lockable hinged doors . All elements shall be arranged so that access may be made to them from the front for easy installation , maintenance and replacement . Openings not used for breakers shall be covered by removable steel plates. Panels shall be suitable for terminating in an approved manner, all necessary cabling whether of copper or aluminum conductor design. It shall be possible to terminate any cable whilst adjacent circuits are energized . All incoming connections , busbars and feeder connections shall be capable of the short time current rating specified and shall meet all required loads plus 25% . The overall height of each tier of cubicles shall be such that the operating handles of all equipment are within the reach of an average person standing at ground level. A separate connection shall be made from the earth bar to the main earth system . Circuit breakers shall be provided with a handle padlock attachment to enable the breaker to be padlocked in the open or closed position . Panel main circuit breaker shall be provided with a trip alarm contact for remote indication . All circuit breakers shall be provided with trip position indication to clearly indicate the breaker trip position . A mimic diagram similar to relevant drawing shall be provided on the front door . LVAC transformer and fuse switch boards shall be modular steel enclosure with lockable and gasketed hinged doors suitable for outdoor mounting . Confidential: This document discloses proprietary information. It may not be reproduced nor disclosed any person, nor used for any purpose, except with the written .permission of MMTE

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5.1.2 Circuit Breakers Circuit breakers shall be of the air break design in accordance with I.E.C. 157, in particular , evidence shall be provided of the performance when switching currents in the critical current range . The A.C. circuit breakers shall be 500 volts A.C. molded case type suitable for 380/220 volt a.c. grounded system , 45oc indoor ambient temperature , draw out model and 25,000 amps symmetrical fault level. 5.1.3 Miniature Circuit Breakers Where miniature circuit breakers are provided for the control and protection of a.c. and d.c. power supply circuits , they shall be designed and tested in accordance with BS 3871 . Miniature circuit breakers in single phase circuits shall be of the single pole type and in d.c. circuits they shall be of the double pole type . Miniature circuit breaker shall , where appropriate , be provided with an auxiliary contact for alarm operation . Miniature circuit breakers shall be designed and mounted in such a manner that inadvertent operation is prevented and the checking of circuit breaker position is facilitated 5.1.4 Operating Mechanisms of Main Circuit Breakers Main circuit breakers shall normally be provided with motor charged spring - operated mechanisms , and provided with electrically operated trip and close facilities so as to be suitable for manual – automatic operation . Appropriate control switches shall be accommodated on the switchboard and suitably labelled to indicate their function . 5.1.5 Fuse Switches Fuse switch units shall comply with the requirements of I.E.C 408 Each switch shall be rated such that it can interrupt the rated load current of the circuit, and where a motor Confidential: This document discloses proprietary information. It may not be reproduced nor disclosed any person, nor used for any purpose, except with the written .permission of MMTE

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circuit is being controlled it shall be capable of switching under locked rotor conditions . C:\Documents and Settings\All Users\Documents\sub-2-9-88\88.8.30\SPEC AC\spec ac.doc

Fuses shall be of the high breaking capacity type in accordance with IEC 269 . Access to fuses shall only be possible when they are de-energized and isolated from the source of supply . Mechanisms shall be of the spring loaded type such that the speed of operation of the switch during opening and closing is independent of the operator and once initiated the operation is completed . In the event of spring failure , operation of the switch shall be possible but without danger to the operator . Indication that the switch is in the ON or OFF position shall be clearly provided . It shall be possible to lock the operating handle in either of these positions . The performance of the fuse switch unit shall match that specified, when the unit is mounted in its cubicle . Isolating switch - fuse units shall be of the air break type and shall have integral fuses . It shall be possible to safely replace the fuses with the busbars alive and the switch open . 5.1.6 Earthing It shall be possible to earth all incoming supplies to the switchboard by means of a fully rated earthing device , either by using the circuit breaker with earthing attachments , a separate earthing truck , or a fixed fully rated earth switch . Busbars and dead end feeders may be earthed by means of a voltage checking device and hand applied portable earths . These shall preferably be applied from the front of the switchboard , but application from the rear will be considered should the former prove impracticable . All not current carrying metal parts shall be connected to the earth bus . 5.1.7 Clearances and Insulation level Clearances and creepage distances in air shall be those stated in I.E.C. 158 , Table 1 and be such that equipment can withstand the dielectric tests specified in I.E.C. 157 without the use of insulating materials on the conductors . Confidential: This document discloses proprietary information. It may not be reproduced nor disclosed any person, nor used for any purpose, except with the written .permission of MMTE

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5.1.8 Thermal performance of Switchboard and Equipment The complete switchboard shall be capable of carrying rated load current without the temperature rise of any portion exceeding a level of 65 and for parts that may be touched by operating personnel shall not exceed a level of 35oc . In determining the load current performance of tiered cubicles it shall be assumed that all circuits are carrying rated currents . The cross sectional area of the busbars may be graded according to the current rating , but shall remain capable of the short time current rating stated elsewhere , without the temperature rise at the end of the test being such as to impair the performance of surrounding materials. 5.1.9 Nameplates Engraved nameplates shall be supplied as follows : (i) Panel nameplates on the front of the panel approximately 15mm x 80 mm . (ii) Nameplates identifying each distribution circuit . 5.1.10 Finish Paint finish color shall be ANSI # 61- light grey . 5.1.11 Accessories A space heater and thermostat shall be provided to prevent condensation . The heater shall be located near the lower part of the panel or cubicle that is installed outdoor. All terminals shall be solder less clamp type. The necessary Ground lugs shall be provided for grounding the panel and all other necessary accessories shall be provided. 5.1.12 Panel characteristic (1) Nominal service voltage and variation (Vrms)

400/230 ±10%

(2) Type of switchgear construction Cubicle -

metal clad

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(3) Number of phases

3

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(4) Type of switchgear enclosure(degree of protection to IEC.144) a) indoor

IP 42

b) outdoor

IP 55

(5) Rated frequency (HZ)

50

(6) Type of incoming and outgoing connections

Cable

(7) System grounding (star point)

Solidly grounded

(8) Transformer rated KVA for station service

2x400

(9) Number of wires

(10)

(10) One minute power frequency voltage withstand level a) Type test KV

2.5

b) Routine test KV

2.5

5.2 Standby Diesel Generator Unit and Associated Equipment 5.2.1 General Diesel generator unit shall be provided for substation , capable of an output of 400 KVA at 380V , 50 Hz (preliminary suggestion) under the site environmental conditions and suitable for operation on gas oil to BS 869 class A2 . The tenderer shall submit with his tender a detailed specification of the diesel generator and associated equipment offered . The standby diesel generator shall be designed for supply to the essential services only , i.e. when the diesel generator is connected, the common services shall be disconnected . 5.2.2 Generator The generator shall be a 4-pole , 3-phase , brushless , synchronous generator for 380 , 50Hz , 1500 rpm. Insulation shall be class F and cooling mode shall be IC 0.1 in accordance with IEC publication 34 . It shall be Y-connected (star) and shall withstand both overload and direct short circuit at the output terminals . The generator shall have an integral (self) A.C exciter with rotating rectifier and static voltage regulator . Confidential: This document discloses proprietary information. It may not be reproduced nor disclosed any person, nor used for any purpose, except with the written .permission of MMTE

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Each generator shall be of the revolving field type . The engine and generator shall be C:\Documents and Settings\All Users\Documents\sub-2-9-88\88.8.30\SPEC AC\spec ac.doc

arranged for mounting on a common bedplate . The generator shall be directly coupled to the engine . The diesel generator shall be connected through a circuit breaker , to be provided under this contract , and a changeover contactor to the main LVAC panel board , as indicated on the drawings . The plant shall be suitable in all respects for local , manual , control and shall be capable of being automatically started up, put on load in the absence of a.c. electrical supplies . The diesel generator shall be started manually and / or automatically and , due to the action of the changeover system the load be connected . The diesel generator shall be capable of running up to its correct speed and voltage before accepting the application of the full load on excitation of the generator. In the event of main supply failure , after a time delay (by a time relay with settings 060S) , a signal will be received and diesel generator shall start immediately . Within 10 seconds after receiving of signal , diesel generator shall be capable of restoring the voltage & frequency to the normal rated values and accepting load upon the closure of generator circuit breaker at oc room temperature . The automatic shutdown shall be provided with a time relay keeping the diesel generator set running for at least 10 minutes after starting . If the generator breaker is closed within 10 minutes period of starting then the automatic shutdown shall be over-ridden and the generator shall be kept running . If the supply returns after the setting time of the time relay 10 minutes, the generator shall immediately be disconnected and the normal supply be connected . The diesel generator set shall be kept running unloaded for two minutes before it is finally shut down . Emergency stop switch shall be located close by the diesel generator switch , This switch shall immediately shut down the set. It shall be lockable in stop position . The neutral point of the generator stator winding will be solidly connected to the power station earthing system .

Confidential: This document discloses proprietary information. It may not be reproduced nor disclosed any person, nor used for any purpose, except with the written .permission of MMTE

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5.2.3 Generator characteristics (1) Rated output (kVA)

400

(2) Nominal voltage (V rms)

220/380

(3) Rated max . voltage (V rms)

230/400

(4) Rated frequency (HZ)

50

(5) Number of phases

3

(6) Power factor (7) Max.steady state change in voltage

0.8 ±2.5%

for instantaneous load increase from zero to full load (8) Max . instantaneous change in

±10%

voltage as defined (9) Max. steady state change in

±2%

frequency (10) Angular velocity (RPM)

1500

5.2.4 Diesel Motor The driving unit shall consist of a direct injection , water - cooled , 4 - stroke diesel motor for 1500 rpm continuous operation , Cooling shall be effected by means of attached cooling radiators for air/ water cooling plus fans . The engine may be required to run for extended periods of time during maintenance . The engine shall be directly connected to the generator by a suitable coupling equipment . 5.2.5 Accessories The following shall be provided for each diesel generator : (1) Electric starter motor (Full automatic) (2) Starting battery (24 v lead / acid ) with a charger of the metal rectifier type Confidential: This document discloses proprietary information. It may not be reproduced nor disclosed any person, nor used for any purpose, except with the written .permission of MMTE

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(3) Reservoir fuel oil tank with minimum running capacity of 200 hours together with C:\Documents and Settings\All Users\Documents\sub-2-9-88\88.8.30\SPEC AC\spec ac.doc

associated pipe work and all fittings and level indicator . This tank shall be supplied from local market . (4) Fuel oil tank for indoor installation with running capacity of 10 hours together with associated pipe work and all fittings for connection to reservoir oil tank and level indicator and free contact for low level fuel alarm . (5) Electrical pump , emergency hand pump and flexible fuel pipe for refilling fuel tank from drums and reservoir fuel tank. (6) Exhaust system , silencer and any other necessary pipe work and fittings . (7) All ancillary equipment , e.g. oil or water heaters , that may be necessary to give reliable operation under the environmental conditions detailed in chapter 2 . (8) Automatic fire protection equipment using carbon dioxide , to extinguish fire in the diesel generator building . (9) Excitation equipment ; brushless system is mandatory . (10) Automatic voltage regulator . (11) Circuit breaker (Contactor) (12) Alarms , protection and tripping equipment . (13) Local control panel , with necessary indicators , gauges, controls and alarm facia , to contain distribution ways for battery chargers , water heaters and similar items . (14) Maintenance tools (to be itemized by tenderer with offer) (15) Operating and maintenance manuals . (16) All spare parts which contractor considers advisable for satisfactory operation of diesel generator . (17) Safety interlocks for electrical or mechanical maintenance . (18) Audible alarm associated with general fault shall be provided in the control cubicle with a ten second time limit device . (19) A second starting attempt shall be applied in the event that the starter pinion does not mesh with the flywheel gear on the first attempt . After three unsuccessfull attempts , the starter shall be locked and “failure to start” alarm shall appear . Confidential: This document discloses proprietary information. It may not be reproduced nor disclosed any person, nor used for any purpose, except with the written .permission of MMTE

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(20) An auto/off/man . (test) switch , lockable in off position , shall be installed on diesel C:\Documents and Settings\All Users\Documents\sub-2-9-88\88.8.30\SPEC AC\spec ac.doc

generator control panel . (21) The lubricating system shall be designed so that oil is continuously filtered and cooled whilst running . Filters shall have easily replaceable elements . (22) The governing system shall be of the centrifugal type with remote (on diesel control panel) and local operated governor control motors that shall be supplied from d.c. source . The range of adjustment shall be not less than plus and minus 5% of rated speed . 6 SPARE PARTS (for AC supply and emergency DG) The following mandatory spare parts shall be provided to cover A.C. system installed where applicable : Twenty (20)

- Lamps for each type used .

one (1)

- Relay for each type used .

Ten (10)

- Intercell connectors .

Ten (10)

- Terminal lugs compression type suitable for 35mm2 and 70mm2 insulated copper conductor

20%

- Auxiliary contacts for each type used .

10%

- Each size of miniature C.B. used .

10%

- Each size of molded case circuit breaker used .

10%

- Each size of fuses used .

Two (2)

- Each size of fused switch used .

Sufficient electrolyte reserve

- for sixty months .

7 SUBMITTALS 7.1 Calculation Sheets Submit four (4) copies of all calculations to establish adequacy , in any respect, of the station service equipment selected for the specified duties under all power system operation conditions from normal to the most severe fault conditions envisaged in accordance with Submittals chapter 3 . Confidential: This document discloses proprietary information. It may not be reproduced nor disclosed any person, nor used for any purpose, except with the written .permission of MMTE

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7.2 Shop Drawings and Manufacturer’s Literature Submit electrical design , fabrication and erection drawings for this chapter in accordance with the Article entitled “Shop Drawings” in submittals chapter 3 . The following shall be considered a minimum . (1) Technical Specification (2) Outline drawings (3) Assembly drawings (4)Control schematic and wiring diagrams for the moulded case C.B’s , Diesel gen . , etc ... (5) Spare parts bulletins (6) Shipping and packing details 7.3 Test Reports Submit four (4) copies of all final type test and routine test reports together with the certification of compliance of the equipment with the type and routine tests stipulated in the applicable standards . 7.4 Maintenance Data and Operating Instructions Submit maintenance manuals for this chapter in accordance with Article entitled “ Maintenance Manuals “ in submittals chapter 3 . 8.0 INSPECTION AND TESTS Perform all inspection , routine and type tests stipulated in applicable standards to ensure that material and workmanship conform to the specification and drawings . Give Client’s representative access to the work for determination or assessment of compliance with the provision of this specification or to witness the contractor’s inspection or tests . Produce a certificate of compliance of the equipment with the design , routine and type Confidential: This document discloses proprietary information. It may not be reproduced nor disclosed any person, nor used for any purpose, except with the written .permission of MMTE

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tests stipulated in the applicable standards . C:\Documents and Settings\All Users\Documents\sub-2-9-88\88.8.30\SPEC AC\spec ac.doc

In addition submit satisfactory evidence of the equipment having successfully undergone at least the following tests , before delivery to site : (1) Operation of all meters and relays using single phase or three phase supply as required, including operation of relay contacts. (2) Energizing of all low voltage control circuits using the appropriate voltage supply , and testing for operation and sequence of operation ; polarity tests where required . (3) Di-electric strength test at 1500 volts A.C. on all wirings . (4) Continuity of all low voltage circuits . Client’s representative reserves the right to have a representative present during final shop and functional testing and , so that it may be possible to take advantage of this , the contractor shall advise the date of test at least sixty (60) days in advance. 9.0 SUPERVISION OVER INSTALLATION,ERECTION & START UP Perform visual inspection before installation to ensure that there is no damage resulting from shipment . Supervise over installations , erection and commissioning of the station service equipment to ensure satisfactory and proper operation in every respect . This supervision shall cover but not be limited to the following where applicable : (1) Installing the equipment in accordance with the drawing and the manufacturer’s instructions . (1) Installing indoor and outdoor A.C. distribution panels . (2) Installing diesel generator and its control cubicles , fuel tanks and accessories . (3) Interconnecting equipment . (4) Notifying Client’s representative in writing as soon as installation of the equipment is completed . (5) On completion of the installation , carrying out all tests subject to the requirements and operating conditions of the client system in co-operation with and in presence of client’s representative and in accordance with a program approved by him . Confidential: This document discloses proprietary information. It may not be reproduced nor disclosed any person, nor used for any purpose, except with the written .permission of MMTE

ELCO STEEL MMTE MME MIYANEH COMPLEX Steel Making Plant Project ASCOTEC

DOCUMENT TITLE

NISCO 230/33 KV SUBSTATION ECHNICAL SPECIFICATION for AC EQUIPMENT

MMAH :Document No

:Designer Document NO :Project Document NO

.Rev

MISP1301ETS016 MWES1U43E000160012

2-1

DATE: NOV. 2009 Page: 18 of 18

(6) Performing field tests and inspections including but not limited to the following : C:\Documents and Settings\All Users\Documents\sub-2-9-88\88.8.30\SPEC AC\spec ac.doc

(a) Visual inspection and checks Hardware and mounting . Grounding connections . Check of fuse and C.B. ratings . Check of thermal relays . Normal output voltage . Alarm Tests Loss of DC. Loss of AC. Earth fault test . (a) AC circuit breakers overcurrent and thermal tests . (b) Continuity test of all low voltage circuits . (c) Meggering on al low voltage circuits . (d) Check of the operation of all meters , relays, instruments, alarms and trips . (e) Functional testing of all equipment . (g) Starting up diesel generator , putting on the load and checking the circuits and functions (h) Fuel motor pump test . 10.0 MEASUREMENT AND PAYMENT Payment of this chapter will be a lump sum for each substation and will be made in accordance with the Schedule of Prices .

Confidential: This document discloses proprietary information. It may not be reproduced nor disclosed any person, nor used for any purpose, except with the written .permission of MMTE