engineering commissioning procedure - uk power...

Document Number: ECP 11-0521

Version: 6.0

Date: 05/01/2015

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ENGINEERING COMMISSIONING PROCEDURE

ECP 11-0521

NORTROLL CABLETROLL 2350 FPI INSTALLATION AND COMMISSIONING PROCEDURE

Network(s): EPN, LPN, SPN

Summary: This document details the installation, testing and commissioning procedures for the Nortroll CableTroll 2350 fault passage indicator.

Owner: Kevin Burt Date: 05/01/2015

Approved By: Steve Mockford Approved Date: 16/01/2015

This document forms part of the Company’s Integrated Business System and its requirements are mandatory throughout UK Power Networks. Departure from these requirements may only be taken with the written approval of the Director of Asset Management. If you have any queries about this document please contact the author or owner of the current issue.

Applicable To

UK Power Networks External

All UK Power Networks G81 Website

Asset Management Contractors

Capital Programme ICPs/IDNOs

Connections Meter Operators

HSS&TT

Network Operations

UK Power Networks Services

Other

Nortroll CableTroll 2350 FPI Installation and Commissioning Procedure


Version: 6.0

Date: 05/01/2015

Revision Record

Version 6.0 Review Date 05/01/2019

Date 05/01/2015 Author Stephen Tucker

Why has the document been updated: Document revised to incorporate revised settings for the LPN interconnected network following an incident investigation. The revised settings will enable operational restriction HSS 406-ORE-41 to be removed from sites where the updated settings are applied.

Associated documents ECP 11-0521a and 0521b updated accordingly with the update of this document.

What has changed: • Overcurrent setting disabled for LPN interconnected network (Clause 11.8). • Test form ECP 11-0521a and ECP 11-0521b updated to incorporate the above change.

Version 5.0 Review Date 30/09/2018


Dip-switch SW4-8 check added. Reviewed for G81 website

Version 4.2 Review Date

Date 08/07/2012 Author John Lowe

Reclassification of document from Installation and Commissioning Manual 5.21


Date 18/03/2011 Author Jerry Wells

Document rebranded



General update to make the document more usable. Remote output settings updated for the Lucy Gemini 2 RTU. New test form for earth fault only units added



Remote output settings corrected. Primary and secondary injection tests modified



Default timer reset changed to 6 hours, mounting details enhanced and RTU test simulators added



Original

© UK Power Networks 2015 All rights reserved 2 of 20



Version: 6.0

Date: 05/01/2015

Contents

1 Introduction ............................................................................................................. 5

2 Scope ....................................................................................................................... 5

3 References ............................................................................................................... 5

4 Abbreviations and Definitions ................................................................................ 6

5 Description............................................................................................................... 6

6 Installation Materials ............................................................................................... 7

7 Test Equipment ....................................................................................................... 7

8 Installation of a CableTroll 2350 with a New Split Core-balance CT .................... 8

9 Installation of a CableTroll 2350 with an Existing Core-balance CT .................. 11

10 Installation of a CableTroll 2350 with Phase CTs ................................................ 11

11 Configuration ......................................................................................................... 12

12 Core-balance CT Tests .......................................................................................... 15

13 Phase CT Tests ...................................................................................................... 16

13.1 Setup ....................................................................................................................... 16

13.2 Primary Injection Earth Fault Test ............................................................................ 17

13.3 Secondary Injection Overcurrent Test ..................................................................... 17

13.4 On-Load Tests ......................................................................................................... 18

14 Final Checks .......................................................................................................... 18

15 Asset Data .............................................................................................................. 18

16 Test Equipment ..................................................................................................... 18

17 Certification ........................................................................................................... 18

Appendix A – Dimensions ................................................................................................ 19

Appendix B – Schematics ................................................................................................ 20

B.1 Typical Schneider RN2/6c FPI Connections ............................................................ 20

B.2 Typical Lucy VRN2/6a FPI Connections .................................................................. 20




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Date: 05/01/2015

Figures

Figure 5-1 – Notroll CableTroll 2350 Fault Passage Indicator ............................................... 6

Figure 8-1 – CableTroll 2350 main PCB with Terminals and Dip Switches Shown ................ 8

Figure 8-2 – Triplex Cable – Cable Screen and Earth through Internal CT ............................ 9

Figure 8-3 – Triplex Cable – Cable Screen and Earth through External CT ........................... 9

Figure 8-4 – Three-core Cable – Cable Screen and Earth through External CT .................... 9

Figure 8-5 – Three-core Cable – Cable Screen terminated before CT and no Earth through CT .......................................................................................................... 9

Figure 8-6 – Split CORE-balance CT Installation ................................................................ 10

Figure 11-1 – CableTroll 2350 Display Card Showing Connections and Dip Switches ........ 13

Figure 13-1 – CT Shorting-link in Place ............................................................................... 16

Figure 13-2 – CT Shorting-link Opened ............................................................................... 16

Figure 13-3 – CT Wiring Lopped Together .......................................................................... 16




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Date: 05/01/2015

1 Introduction 1.1 This document details the installation, testing and commissioning procedures for

the Nortroll CableTroll 2350 fault passage indicator (FPI). These tests shall be satisfied before the FPI can be accepted as fit for service and energisation.

1.2 This procedure shall be carried out by the Commissioning Engineer or his appointed representative, who shall be Competent Person having appropriate training and experience.

1.3 This procedure shall be carried out in accordance with the requirements of the UK Power Networks Distribution Safety Rules.

1.4 This procedure shall be carried out with regard to the requirements and recommendations of the manufacturer. If conflict exists between the requirements of the manufacturer and those of UK Power Networks the matter shall be referred to Asset Management (or your UK Power Networks nominated contact).

1.5 The results of all observations, tests, adjustments and all relevant remarks shall be recorded on the associated test form.

2 Scope 2.1 This procedure and the associated test form apply to the CableTroll 2350 fault

passage indicator. The installation of a split core-balance current transformer (CT) is also covered.

2.2 This procedure is intended for use by UK Power Networks field staff, contractors and external connection providers.

3 References 3.1 This procedure should be read in conjunction with the following references:

• EOS 05-6003 Fault Passage Indicators. • Nortroll CableTroll 2350 User Guide (available from Alfresco Engineering

Library > Reference Library > Manufacturers > Nortroll).

3.2 This procedure should be used with the following test forms:

• ECP 11-0521a Nortroll CableTroll 2350 FPI Overcurrent and Earth Fault Test Form.

• ECP 11-0521b Nortroll CableTroll 2350 FPI Earth Fault Only Test Form.




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Date: 05/01/2015

4 Abbreviations and Definitions 4.1 The following abbreviations and definitions are used throughout this procedure.

Term Definition

Alfresco UK Power Networks Document Library

ART UK Power Networks Asset Registration Team

CT Current Transformer

FPI Fault Passage Indicator

RTU Remote Terminal Unit

5 Description 5.1 The CableTroll 2350 (Figure 5-1) is a battery powered fault passage indicator for

detecting overcurrent and earth faults on underground cable networks operating at voltages up to and including 36kV. It can be used with either three FPI phase CTs (fitted as standard in the left-hand cable box of all new ring main units) or, where phase CTs are not fitted, a core-balance CT can be used (but this will only provide an earth fault indication). Therefore the CableTroll 2350 is suitable as a replacement for older type earth fault indicators (EFI) using a core-balance CTs.

Note: New core-balance CTs have a 60/1 ratio, however, existing core-balance CTs with a 60/1 or a 40/1 ratio can also be found on the networks.

Figure 5-1 – Notroll CableTroll 2350 Fault Passage Indicator

EarthFault

Overcurrent

Test

Reset

SN:Manufactured:

Battery date:Batt

1 2 30

CableTroll 2350R

Made in Norway

CE




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5.2 The CableTroll 2350 includes the following functionality:

• Two high visibility LEDs for the indication of an overcurrent or earth fault. • An output contact for remote indication. • A self-reset. • A local and remote reset. • A local test facility. • Built-in commissioning tests. • 10 year battery life.

5.3 The CableTroll 2350 has two built in tests to assist with commissioning. The first test checks whether there is any zero sequence (residual) current flowing. Zero sequence current generally only flows during an earth fault; however, there will always be a low level of zero sequence current flowing due to network imbalance. This test determines whether the zero sequence current is above 15A.

5.4 The second test checks for load current (this test is only applicable if three 500/1 phase CTs are being used and the circuit load is above 15A per phase) and is an indication that the CTs are connected correctly.

6 Installation Materials 6.1 The following materials are required to undertake the installation of a CableTroll

2350 using a split core-balance CT:

• Nortroll CableTroll 2350 (14731H). • Split core-balance CT (14733C). • 1.5mm2 2-core PVC insulated and PVC sheathed cable (BS 6500:1994 code

3182Y). • 1.5mm2 4-core PVC insulated and PVC sheathed cable - only required if remote

indication/reset is used (BS 6500:1994 code 3184Y). • 2 BA nuts, bolts and washers for securing the CableTroll 2350. • Contact grease.

Note: If the CableTroll 2350 is supplied with the switchgear these items are not required.

7 Test Equipment 7.1 The following test equipment is required to carry out the tests detailed in this

procedure:

• Secondary Current Injection Test Set (range 0.1A to 100A). • Injection device capable of injecting 60A (core-balance CT installations only). • RTU simulator (LPN Remsdaq RTU only).




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8 Installation of a CableTroll 2350 with a New Split Core-balance CT 8.1 Connect a 1.5mm2 2-core cable to the CT via the gland.

8.2 Separate the two halves of the CT by removing the stainless steel band.

8.3 Position the CT correctly around the cable, with particular reference to Paragraph 8.11 - Figure 8-2, Figure 8-3, Figure 8-4 and Figure 8-5. Fit the jubilee clip supplied with the CT loosely around the cable.

8.4 Fit the removable half of the CT in position and secure to the cable using the cable clamps and jubilee clip.

8.5 Remove the front cover of the CableTroll 2350.

8.6 Mount the CableTroll 2350 on the switchgear supporting legs on the side nearest to where the CT will be installed. The CableTroll 2350 only requires two of the four fixings to be used to secure it in place. Note: The CableTroll 2350 box has four fixing holes, one in each corner with 110mm between vertical centres and 90mm between horizontal centres. Full dimensions are given in Appendix A.

8.7 Connect the CT to terminals J3/S1 and J3/S2 on the CableTroll 2350 (refer to Figure 8-1) via the gland, ensuring there is sufficient cable to reach the CT position.

Figure 8-1 – CableTroll 2350 main PCB with Terminals and Dip Switches Shown

8.8 Before the other half of the CT is installed, wipe the contact faces to ensure they

are clean and apply thin coating of contact grease to the faces.

8.9 Mate the two halves of the CT together ensuring the locating marks agree and that any neoprene washers are not trapped between the faces.

8.10 Tighten the stainless steel band securing the two halves of the CT.

SW4

J8

J6 J3

J4

J5

J2 J1

2: External Indication 3: External Indication

Battery Terminal

1: External Reset 2: External Reset

S2: CT 1 S1: CT 1 S2: CT 2 S1: CT 2

S1: CT 3 S2: CT 3

Display Card Connector

PC Download Connector

500/1 60/1 40/1

500/1

500/1

S1

Battery Reset Button

SW3




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8.11 If the cable earth screen passes through the CT, the earth shall also pass through

the CT. Refer to examples in Figure 8-2, Figure 8-3 and Figure 8-4. This is to ensure that currents in the screens are cancelled, and that the CT only measures the earth fault current in the cable cores. Note: On modern switchgear the switchgear earth stud is insulated from the gland plate and the cable screen is terminated onto the insulated earth stud, either inside or outside the cable box.

Figure 8-2 – Triplex Cable – Cable Screen and Earth through Internal CT

Figure 8-3 – Triplex Cable – Cable Screen and Earth through External CT

Figure 8-4 – Three-core Cable – Cable Screen and Earth through External CT

Figure 8-5 – Three-core Cable – Cable Screen terminated before CT and no Earth through CT

Insulatedearth stud

Core-balanceCT

Insulatedearth stud

Core-balanceCT

Insulatedcablegland

Core-balanceCT

Insulatedcablegland

Core-balanceCT

Cable screenbrought outfor terminationbefore CT




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Date: 05/01/2015

8.12 If the cable earth screen does not pass through the CT, as shown in Figure 8-5,

there is no need for the switchgear earth to pass through the CT.

8.13 Where the earth passes through the CT rotate the CT so that the edge of the removable part of the CT lines up with the edge of the earth as shown in Figure 8-6. This should make an angle of 70° between the earth and the terminal box for optimum performance.

Figure 8-6 – Split CORE-balance CT Installation

8.14 Adjust the CT support bracket(s) so that the cable is centrally positioned in the CT

and re-tighten.

8.15 If required, connect the remote output and remote reset, from the RTU, to terminals J6 and J8 respectively (refer to Figure 8-1) using a 1.5mm2 4-core cable.

8.16 Check all connections and glands are adequately tightened.

8.17 Commission and test CableTroll 2350 according to Sections 11 and 12.

70 degrees(angle for optimumperformance)

Locating marks

Jubilee clip

Removable part

Earth

Neoprene washers




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9 Installation of a CableTroll 2350 with an Existing Core-balance CT 9.1 Disconnect the CT from the old earth fault indicator.


9.3 Mount the CableTroll 2350 on the switchgear supporting legs on the side nearest to the CT. The CableTroll 2350 only requires two of the four fixings to be used to secure it in place. Note: The CableTroll 2350 box has four fixing holes, one in each corner with 110mm between vertical centres and 90mm between horizontal centres. Full dimensions are given in Appendix A.

9.4 Connect the CT to terminals J3/S1 and J3/S2 on the CableTroll 2350 (refer to Figure 8-1) via the gland, ensuring there is sufficient cable to reach the CT position.

9.5 If required, connect the remote output and remote reset, from the RTU; to terminals J6 and J8 respectively (refer to Figure 8-1).



10 Installation of a CableTroll 2350 with Phase CTs 10.1 Generally the CableTroll 2350 will have already been installed by the switchgear

manufacturer and connected to the phase CTs in the cable box. However, if this is not the case follow the steps below.


10.3 Mount the CableTroll 2350 on the switchgear supporting legs on the side nearest to the CT, generally this will be adjacent to ring switch one. The CableTroll 2350 only requires two of the four fixings to be used to secure it in place. Note: The CableTroll 2350 box has four fixing holes, one in each corner with 110mm between vertical centres and 90mm between horizontal centres. Full dimensions are given in Appendix A.

10.4 Connect the CTs to terminals J3/S1, J3/S2, J4/S1, J4/S2, J5/S1 and J5/S2 on the CableTroll 2350 (refer to Figure 8-1) via the gland according to the schematics shown in Appendix B.

10.5 If required, connect the remote output and remote reset, from the RTU, to terminals J6 and J8 respectively (refer to Figure 8-1) according to the schematics shown in Appendix B.






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11 Configuration 11.1 Record the substation and CableTroll 2350 details on the relevant test form

ECP 11-0521a (overcurrent and earth fault) ECP 11-0521b (earth fault only).

11.2 Carry out a visual inspection of the CableTroll 2350 to check that it is undamaged and correctly mounted and secured.

11.3 Remove the front cover.

11.4 Connect the battery and press the Battery Reset button on PCB.

11.5 Press the Test button on the front of the unit. The earth fault and overcurrent LEDs should be illuminated in turn followed by LED 0 which should be green (if LED 0 is red the battery test has failed and the battery should be replaced).

11.6 The CableTroll 2350 has a number of configurable settings. The default settings and the available settings are shown below.

Parameter Default Dip-switch Options

Overcurrent Threshold 625A SW3-1 = 0, SW3-2 = 0, SW3-3 = 1

OFF, 250A, 375A, 500A, 625A, 750A

Earth Fault Threshold 50A SW3-6 = 0 OFF, 50A

CT Type 500/1 SW3-8 = 0 500/1, 60/1

Earth Fault CT Type 60/1 SW3-7 = 0 60/1, 40/1

Timer Reset 6h SW3-4 = 0, SW3-5 = 1 OFF, 3h, 6h, 12h

Remote Output Fleeting SW4-1 = 1 Fleeting, Latched

Remote Reset Yes - None

Output Relay H SW4-8=1 F, H 11.7 The settings can be changed using the dip-switches inside the unit. The function of

each dip-switch is shown on the display card on the inside of the lid (refer to Figure 11-1).




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Figure 11-1 – CableTroll 2350 Display Card Showing Connections and Dip Switches

11.8 Select the appropriate overcurrent setting according to the table below using dip-

switches SW3-1, SW3-2 and SW3-3.

Parameter Network Setting SW3-1 SW3-2 SW3-3

Overcurrent Threshold

LPN Interconnected OFF 0 0 0

LPN Non-interconnected 625A 0 0 1

EPN, SPN 625A 0 0 1

EPN, SPN beyond pole mounted reclosers where NOP fault level ≤25MVA

250A 1 0 0

Note: If the CableTroll 2350 is only being used as an earth fault indicator set the overcurrent threshold to OFF.

11.9 Check that timer reset is set to 6 hours according to the table below using dip-switches SW3-4 and SW3-5.

Parameter Setting SW3-4 SW3-5

Timer Reset 6h 0 1 11.10 Check that the earth fault has been enabled according to the table below using

dip-switch SW3-6.

Parameter Setting SW3-6

Earth Fault Enable 0




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11.11 Select the appropriate CT ratio according to the table below using dip-switches

SW3-8 and SW3-7. FPI phase CTs have a 500/1 ratio and new core-balance CTs have a 60/1 CT ratio.

Parameter Setting SW3-8 SW3-7

CT Ratio 500/1 0 0

60/1 1 0

40/1 1 1 11.12 If the CableTroll 2350 is connected to an RTU select the appropriate remote

output type according to the table below using dip-switch SW4-1.


Lucy Gemini 2 RTU Remote Output Latched 1

Remsdaq RTU Remote Output Latched 1 11.13 Check that the output relay type is set correctly according to the table below using

dip-switch SW4-8. This parameter was introduced on all units from September 2011 which is labelled with an ‘H’. This parameter should be correctly set in the factory.


Output relay type F (no H label fitted)

Off 0

Output relay type H (H label fitted) On 1 11.14 On completion of the configuration press the Reset button on the front of the unit.

11.15 Record the selected settings on the test form.




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12 Core-balance CT Tests 12.1 Carry out a primary injection test from the CT to test the earth fault threshold.

12.2 Connect the injection test set through the core-balance CT. Increase the injection current until earth fault LED on the CableTroll 2350 illuminates – this should be around 60A for a 60/1 or 40/1 CT.

12.3 Record the actual current on the test form.

12.4 If applicable, confirm that the appropriate indication is shown on the RTU or RTU simulator.

12.5 Reset the CableTroll 2350.

12.6 Disconnect the test set.




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13 Phase CT Tests

13.1 Setup

13.1.1 Check the 500/1 phase CTs have been satisfactorily tested during the switchgear commissioning.

13.1.2 Check that any manual CT shorting-link has been opened or removed for the 500/1 phase CTs. An example is shown in Figure 13-1 and Figure 13-2. Note: The CT shorting arrangement used will be dependent on the type of switchgear.

Figure 13-1 – CT Shorting-link in Place Figure 13-2 – CT Shorting-link Opened

13.1.3 Check that the CT (and, if fitted, the remote output and remote reset) wiring is

correctly terminated in the CableTroll 2350. Note: If there are only four cores for the CT wiring, terminals J3/S2, J4/S2 and J5/S2 in the CableTroll 2350 must be looped together, an example is shown in Figure 13-3.

Figure 13-3 – CT Wiring Lopped Together

13.1.4 If appropriate, check that the RTU or RTU simulator (LPN only) is connected to the

switchgear.




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13.2 Primary Injection Earth Fault Test

13.2.1 Carry out a primary injection test from the relevant cable box to test the earth fault threshold.

13.2.2 Close the earth switch associated with the cable box under test.

13.2.3 Connect the injection test set between the L1 phase bushing in the cable box and switchgear earth. Increase the injection current until earth fault LED on the CableTroll 2350 illuminates – this should be around 50-60A.

13.2.4 Record the actual current on the test form.

13.2.5 If applicable, confirm that the appropriate indication is shown on the RTU or RTU simulator.

13.2.6 Reset the CableTroll 2350 and repeat for phase L2 and L3. The earth fault threshold should be similar in all three tests.

13.2.7 Disconnect the test set.

13.3 Secondary Injection Overcurrent Test

13.3.1 Carry out a secondary injection test from the CT terminal block on the switchgear to test overcurrent threshold.

13.3.2 Check that one side of each CT is connected together – most switchgear is supplied with this configuration but if this is not the case use a shorting-link as necessary.

13.3.3 Connect the injection test set across the L1-L2 phase CT at the CT terminal block. Increase the injection current until overcurrent LED on the CableTroll 2350 illuminates – this should operate according the values given in the table.

Setting (A) 250 375 500 625 750

Approx Secondary Operating Current (A) 0.5 0.75 1 1.25 1.5 13.3.4 Record the actual current on the test form.

13.3.5 Reset the CableTroll 2350 and repeat for phase CTs L2-L3 and L3-L1. The overcurrent threshold should be similar in all three tests.

13.3.6 If applicable, remove the shorting link applied in step 13.3.2.

13.3.7 Disconnect the test set.




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13.4 On-Load Tests

13.4.1 Carry out these tests with both ring switches closed after the switchgear is connected to the HV network and energised.

13.4.2 Press and hold the test button, press the reset button and then release both to initiate the built-in commissioning tests. LEDs 0, 1, 2, and 3 will light briefly and indicate the following:

• Zero sequence test – if LED 0 is green the zero sequence current is below 15A and is okay. If LED 0 is red the zero sequence (earth fault) current is above 15A and indicates that there is a problem with the CTs or CT wiring or there is an earth fault on the network. This should be investigated further.

• Load current check – if LED 1, 2 or 3 is yellow a load current above 25A is flowing in the respective phase. If the actual load at the site is expected to be above 25A on each phase and any of the LEDs 1, 2 or 3 are not illuminated then this indicates that the CTs are incorrectly connected or that there is a wiring fault between the CTs and the CableTroll 2350. This should be investigated further.

14 Final Checks 14.1 Check the CT shorting-link has been removed if applicable.

14.2 Check all connections secure.

14.3 Check front cover is secure.

15 Asset Data 15.1 Complete the asset data form and either send it to the Asset Registration Team

(ART), email it to the appropriate mailbox ([email protected], [email protected], [email protected]) or send it to your UK Power Networks nominated contact.

16 Test Equipment 16.1 Record the purpose, make, type and serial number of all test equipment used

during commissioning on the test form.

17 Certification 17.1 When all the tests have been satisfactorily completed, sign and date the test form.

Place a copy of the test form on-site in a plastic wallet and in a secure location.


mailto:[email protected]





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Appendix A – Dimensions

AA Cable Entry

Section A-A

120

120




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Appendix B – Schematics Typical FPI connections for secondary switchgear are shown below. Refer to the switchgear commissioning procedures ECP 11-0511 and ECP 11-0512 for more detailed schematic drawings.

B.1 Typical Schneider RN2/6c FPI Connections

B.2 Typical Lucy VRN2/6a FPI Connections


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