sp 00 e 0012 rev 0 hv switchgear

7/27/2019 SP 00 E 0012 Rev 0 HV Switchgear

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OWNERKANDHKOT FIELD GAS COMPRESSION STATION (KFGCS)

PROJECT

CONTRACTOR

Document Title:SPECIFICATION FOR HIGH VOLTAGE

SWITCHGEAR

Date: 03/09/2007 Document No: SP-00-E-0012 Rev: 0 Class: I Sheet 1 of 19

0 Issued for Construction 03/09/2007 ARS SN ShS LiuXG

A Issued for Approval 17/07/2007 ARS SN ShS LiuXG

Rev Description Date Prepared Checked Approved Client Owner

SPECIFICATION FOR HIGH VOLTAGESWITCHGEAR


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CONTENTS

SPECIFICATION FOR HIGH VOLTAGE SWITCHGEAR 1

1 SCOPE 3

1.1 Introduction................................................................................................................3

1.2 Vendor Responsibilities..............................................................................................3

1.3 Scope of Supply.........................................................................................................3

1.4 Conflict of Documentation..........................................................................................4

1.5 Exceptions to Specifications / Compliance Statement................................................4

1.6 Quality System...........................................................................................................4

2 GENERAL REQUIREMENTS 5

2.1 Codes and Standards.................................................................................................5

2.2 Data Sheets............................................................................................................... 6

2.3 Certification................................................................................................................6

3 SITE CONDITIONS 6

3.1 Environmental............................................................................................................ 6

3.2 Hazardous Area Classification...................................................................................6

3.3 Safety.........................................................................................................................6

4 DESIGN AND CONSTRUCTION REQUIREMENTS 7

4.1 System Voltage and Frequency.................................................................................7

4.2 General......................................................................................................................7

4.3 Construction...............................................................................................................7

4.4 Controls and DC Control Circuit Philosophy...............................................................9

4.5 Bus-Bars.................................................................................................................. 10

4.6 HV Circuit Breakers..................................................................................................10

4.7 Potential Transformers (PTs)...................................................................................11

4.8 Current Transformers (CTs).....................................................................................12

4.9 Trip Circuit Supervision............................................................................................12

4.10 Protective Relays...................................................................................................12

4.11 Instruments............................................................................................................ 134.12 Auxiliary Switches, Devices and Wiring..................................................................14

4.13 Terminals............................................................................................................... 15

5 ACCESSORIES 15

5.1 DC Power.................................................................................................................16

5.2 Marking and Finishing..............................................................................................16

5.3 Inspection and Testing.............................................................................................17

5.4 Factory Acceptance Testing (FAT)...........................................................................18

5.5 Certificates of Acceptance........................................................................................19


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1 SCOPE

1.1 Introduction

This specification covers the design, construction and supply of a High VoltageSwitchgear assembly (HV Switchgear).

1.2 Vendor Responsibilities

Vendor shall be responsible for the complete design, engineering, manufacture, supply,

inspection, testing, documentation and preparation for shipment of the HV Switchgear, infull compliance with all applicable design Codes and Standards, including those listed inSection 2 of this document and the requirements of the certifying authority, if applicable.

Purchasers approval of the Vendors drawings/documents does not in any way affectVendors full responsibility to supply strictly in accordance with Project specification,codes and standards.

This specification shall not relieve the Vendor of any responsibility to provide equipmentand services that are suitable for the intended duty.

1.3 Scope of Supply

The Vendor shall supply the following:

Factory design, fabrication, assembly, factory acceptance testing, packaging and

preparation for shipment, shipment to the site of the specified HV Switchgear

DC System consisting of batteries, chargers and Distribution Board for protection,

control and indication circuits of the HV Switchgear

Design drawings and data including Single Line Diagrams, Schematics, Wiring

Diagrams, Termination Diagrams, Bill of Materials, Protection Schematics andGeneral Arrangement Drawings

Completed Data Sheets

As Constructed drawings

Installation, Operation, Maintenance and Commissioning Manuals

Manufacturers Data Report (MDR) Manual

Erection, testing and commissioning supervision services.

Each unit shall be a self-contained package inclusive of all equipment necessary forplacing the units into immediate service.


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The review and approval of any drawings, procedures or documents referred to in thisSpecification shall only indicate acceptance of general requirements and shall not relievethe Vendor of its obligations to comply with the requirements of the Purchase Order.

Compliance by the Vendor with the provisions of this Specification does not relieve himof the responsibility of furnishing equipment of proper design, electrically andmechanically suited, to meet the operating requirements under the specified serviceconditions.

1.4 Conflict of Documentation

In the event of a conflict between this specification and any other documentation, the

Purchaser shall be made aware for clarification, before commencement of design orfabrication.

1.5 Exceptions to Specifications / Compliance Statement

Deviations to the requirements of this Specification and the associated standards anddocuments to which the equipment shall be manufactured and tested; must be stated byVendor in writing at the bid stage.

In the absence of such a statement, it is considered that the requirements of theSpecification are met without exception.

Any shortcomings that are identified during or on the completion of fabrication shall becorrected by Vendor at the Vendors expense.

1.6 Quality System

A quality control program shall be submitted to the Purchaser for review and approvalprior to commencement of the work. The quality program shall include allSubcontractors.

The Vendor shall maintain an effective program for quality assurance and quality control,planned and developed in conjunction with all manufacturing, storage and applicationfunctions necessary to meet the requirements of the Purchase Order and thisSpecification.

The Quality Plan shall ensure that quality requirements are determined prior tocommencement of the work and subsequently satisfied throughout.

The Suppliers quality system and quality control procedures shall generally conform tothe requirements of ISO 9000/9001/9002; whichever is applicable.


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2 GENERAL REQUIREMENTS

2.1 Codes and Standards

The design and installation shall comply with the following Standards and Codes ofPractice:

IEC 60044 Instrument Transformers

IEC 60056 High-voltage alternating-current circuit breakers

IEC 60129 Alternating current disconnectors and earthing switches

IEC 60186 Voltage transformersIEC 60255 Electrical Relays

IEC 60265 High Voltage Switches

IEC 60282 High Voltage Fuses

IEC 60298 AC metal-enclosed switchgear and control gear for rated voltagesabove 1 kV and up to and including 52 kV

IEC 60332-1 Tests for electric cables under fire conditions

IEC 60420 High Voltage alternating current switch fuse combinations

IEC 60470 High-voltage alternating current contactors and contactor-based

motor-starters

IEC 60427 Synthetic testing of high voltage alternating current circuit breakers

IEC 60529 Degrees of protection provided by enclosures (IP Code).

IEC 60632 High Voltage Motor Starters

IEC 60694 Common Specifications for High-Voltage Switchgear andControlgear Standards

Where the standard consists of multiple parts, the Vendor shall conform to each andevery part.

Where there is no applicable code or standard as mentioned above, codes or standardspublished by the following international organisations shall be used:

International Electro-technical Commission (IEC)

Harmonised European Standards (EN)

British Standards Institute (BSI)


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2.2 Data Sheets

Purchasers equipment Data Sheets shall form a part of this Specification. Theequipment shall comply with all the requirements of the Data Sheets DS-00-E-0017.The Vendor shall complete all information requested on the Data Sheets.

2.3 Certification

The HV Switchgear shall be fully type tested by ASTA or KEMA or other recognisedindependent certification organization (subject to Purchasers approval) for adequateshort circuit withstand and allowable temperature rise. The HV Switchgear shallpreferably be type tested for arc fault containment. The requirement for arc fault

containment shall become mandatory when called for on the Data Sheet.

Vendor shall furnish details of certification with copy of the type test certificatesdemonstrating compliance with the latest revision of applicable standards forPurchasers approval.

3 SITE CONDITIONS

3.1 Environmental

Refer to the Specification for Environmental Design Conditions Doc No. SP-00-M-0020.

3.2 Hazardous Area Classification

The HV Switchgear will be installed indoors in an unclassified (non-hazardous) location.

3.3 Safety

The HV Switchgear shall conform to the following requirements:

The switchboard enclosures shall comply with IEC60298, Annexure AA with regard to

mechanical strength and ability to contain an arc fault. The test condition shall be inconformity with accessibility Type A, and the switchgear shall meet assessmentcriteria 1 to 6 inclusive.

Switchgear and control equipment shall be designed to minimize risk due to internal

short circuits and to ensure personnel safety during all operating conditions,inspections and maintenance.

To minimize fire hazards, halogen-free, flame-retardant materials shall be used

where appropriate.

Toxic materials (such as asbestos, polychlorinated biphenyls (PCBs), mercury, and

the like), shall not be used.

Operation of the switchgear shall be carried out with the cubicle door closed. This

shall include racking in and out of the circuit breaker and contactor trucks, and

application of the earth switch.


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4 DESIGN AND CONSTRUCTION REQUIREMENTS

4.1 System Voltage and Frequency

4.1.1 System Voltage

WAPDA: 11000V, 3 Phase, 3 Wire, 50 Hz

4.1.2 Steady state variations

Steady state (long-term) voltage variation: +5%, -10%

Steady state (long-term) frequency variation: +/-2%

4.1.3 Transient state variations

Transient voltage variation: +/-20%

4.2 General

The HV Switchgear shall have bus bar configuration as shown on single line diagram.The design shall allow for the future extension of the busbar and addition of new panelsat both ends of the switchgear.

4.3 Construction

The switchgear shall be metal clad enclosed, free standing, dead-front, indoor type, dustand vermin-proof, standardised to form a single assembly with a common bus-bar andshall incorporate vacuum breakers/contactors.

Enclosures shall have a minimum degree of protection IP41 as defined in the IEC 60529without using the floor as part of the enclosure.

The design shall allow for personnel to work safely within an empty switching devicecompartment, or one which has the control device assembly removed, with the bus

energised. The main bus and risers shall be fully segregated and plug-in contacts forthe devices shall have minimum openings.

Incoming and outgoing sections shall be supplied with air insulated main power cableterminating compartments, arranged for bottom cable entry unless specified otherwiseon the Data Sheets. All covers for the switchgear shall be sealed with gaskets (includingback & side covers). Gaskets shall be non-deteriorating rubber or neoprene material.

The switchgear shall be provided with hinged front panel doors. The compartment doorsshall be attached with at least two fixings. Doors and covers of HV compartments whichmay be opened without the use of tools shall be provided with mechanical interlock andpadlocking facilities. It shall be possible to gain safe access to breaker / control circuit


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compartments while HV circuits are live. No LV components and associated LV wiringshall be located in HV compartment. The following padlocking facilities shall be provided:

All circuit breakers and contactors in the OFF and TEST positions

All busbar and circuit earthing switches.

The structure shall be provided with internal barriers to prevent spreading the damagebetween panels when faults occur. These barriers shall also segregate power andcontrol compartments to confine electrical disturbances and faults.

The switchgear shall be factory assembled in one section or as otherwise required by

shipping limitations and shall be arranged for a minimum of field assembly. Theswitchgear shall be suitable for future addition of units on each end.

Suitable means, properly interlocked, shall be provided for earthing as follows:

Earthing of the line side of the main incoming feeder.

Earthing of the load side of the outgoing feeder breakers and motor starters.

Earthing of bus bars.

Any of the following earthing systems is acceptable:

A fault rated earth switch mechanically interlocked with the circuit breaker / contactor

to prevent inadvertent earthing when the circuit breaker / contactor is closed.

An adequately rated circuit breaker able to select an earth position.

A suitable draw out type fault rated earthing truck replacing the circuit breaker.

All earthing switches shall be fault rated to the same fault level as the switchgear.

The switchgear shall be provided with a common copper ground bus. The ground busshall extend through the entire length of the composite switchgear and shall be providedwith facilities for connection to Purchasers copper earth system.

All equipment shall be interlocked to ensure safe operation. Warning notices shall bemounted on all devices that may be damaged or cause harm to personnel or equipmentif operated incorrectly.

The switchgear shall be mechanically and electrically interlocked to prevent:

Removal of the circuit breaker from its normal operating position when the breaker is

in its closed position.

Switching of earth switch when circuit breaker is in service operation.


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Disconnecting of Low Voltage (LV) or auxiliary system when circuit breaker is inoperation.

Switching ON circuit breaker when earth switch is in closed position.

Insertion of the circuit breaker into its normal position when the earthing switch is in

its closed position.

Closing of the earth switch when in service position.

Closing of the circuit breaker, unless the primary disconnecting devices are in full

contact, or separated by a safe distance.

Grounded metal safety shutters shall be provided to automatically cover all bus barcontacts and insulating spouts or isolating contacts whenever circuit breakers arewithdrawn. The opening and closing of the shutters shall be by positive mechanicalmeans whilst racking-in or out the circuit breaker or contactor.

All sections shall be designed and arranged for lifting from the top, which may utiliseremovable lifting brackets. Provisions shall be made for lifting the switchgear assemblyand bolting it into position.

All items of equipment shall be arranged in a logical manner to facilitate ease ofoperation, maintenance and repair.

All metallic non-current carrying parts, not inherently bonded together, shall be bondedtogether and connected to the earth bus.

Arc containment barriers shall be provided by means of internally enclosed chambers.

Hinged and draw out type compartment doors shall be effectively earthed through aflexible connection or a wiping contact.

Proper clamps and supports shall be provided inside the cable and connection cubiclefor fixing and supporting incoming and outgoing cables with suitable clearances.

4.4 Controls and DC Control Circuit Philosophy

Vendor shall supply DC System and DC Distribution Board as part of HV Switchgear.

a) The close and trip circuits of the HV circuit breakers and contactors shall besupplied from DC distribution board supplied with the switchgear. DC control circuitsfor all incomers and outgoing feeders shall be supplied directly from the distributionboard (one DC circuit per feeder). Each panel shall have separate trip and closecircuits. Each circuit shall be protected separately by MCB (all MCBs shall beequipped with auxiliary contacts wired to the terminal strip).

b) It shall be possible to isolate either the trip or close circuit in any panel, withoutaffecting any subsequent panels. The sub-circuit for the DC spring charging motor

shall be fuse protected. Protection shall be coordinated with the closing circuit MCB.


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c) Vendor shall size and supply DC battery charger, batteries, battery rack and DCdistribution board. The battery bank shall be sized to support the switchboard DCSystem for a duration stated in Section 5.1.

Vendor shall provide clamps and supports inside the cable connection cubicle for fixingand supporting incoming and outgoing cables with suitable clearances.

4.5 Bus-Bars

The bus-bars shall be hard-drawn high conductivity copper with high-pressure boltedtype connections.

The busbar system (main and droppers) shall be fully insulated throughout. The busbarinsulation shall be continued into the main switching device compartment as far aspracticable. Insulation material shall be epoxy coating type material, flame-retardant,non-hygroscopic and non-tracking type. Tapered bus-bars shall not be acceptable.Factory supplied HV rated insulating tape shall be utilised for busbar joints on site.

All bus-bars, including plug-in stubs and insulation, shall withstand thermal and magneticeffects of the specified short-circuit current imposed on the electrical system for theperiod stated in the Data Sheets.

The main earth bus-bar shall be sized to withstand the thermal and dynamic stresses ofa bolted earth fault equal to the switchgear rating for the period stated in the DataSheets.

Where allowance for thermal expansion is required, bus-bars shall be joined by doublebolted connections with flexible joints.

Bus-bar ends shall be drilled and finished for future extensions at both ends.

The bus-bars and taps of feeder circuits shall be rated to carry the maximum rating ofthe circuit breaker.

Bus-bar droppers shall have the same cross section for their full length.

The sequence of the busbars shall be red-white-blue, top to bottom, left to right andback to front, all relative to the front of the switchboard.

4.6 HV Circuit Breakers

The circuit breakers shall be motor operated spring charged vacuum circuit breakers (asspecified on the Data Sheet) withdrawout type construction. Circuit breakers shall besuitable for uninterrupted duty, short circuit breaking capacity (including DC component)and withstand over-voltage transients when interrupting running currents of small motorsor the magnetising current of the transformers.


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All HV circuit breakers shall be fully removable without the need for handling trucks orthe manual disconnection of wire plugs or sockets. Direct driven mechanical indicationof the switching device position shall be visible from the switchgear front. Indication LightEmitting Diodes (LEDs) shall also be provided.

Control supply voltage of the circuit breaker shall be DC Voltage mentioned in the DataSheet.

Each circuit breaker shall be mechanically and electrically trip-free and have a provisionfor manual closing and tripping.

All circuit breakers of identical current rating shall be interchangeable.

Circuit breakers shall have surge arrestors on the outgoing feeders, only ifrecommended by the Vendor.

Mechanical counters shall be provided for all circuit breakers.

The circuit breakers shall include all necessary auxiliary switch contacts and shall havethe following contacts, wired to accessible terminal blocks for Purchaser's use:

Minimum four (4) normally open contacts

Minimum four (4) normally closed contacts

The circuit breakers shall have an anti-pumping feature and manually reset lockoutrelays to prevent circuit breaker re-closing when tripped by protective devices.

Mechanical indications shall be provided on the circuit breakers to indicate operatingposition of the breaker.

4.7 Potential Transformers (PTs)

Potential transformers shall be of epoxy resin or butyl rubber moulded type and shallhave the same insulation level as the switchgear. The accuracy shall be Class 1 formetering PTs as per IEC 60186 or as per equivalent AS. The accuracy class for

protection PTs shall be 3P as per IEC 60186 or as per equivalent AS. Vendor shallprovide PTs with better accuracy class where required for specific applications.

Each potential transformer shall be protected with current limiting primary and secondaryfuses.

Each set of potential transformers, and its protective fuses shall be assembled in aseparate compartment, and so arranged that the unit can be readily withdrawn from theoperating position. In the withdrawn position, the potential transformer and fuses shallbe completely disconnected from service and all exposed parts visibly grounded.

All live parts shall be inaccessible to personnel, or so interlocked that these shall be

accessible only in the de-energised condition.


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4.8 Current Transformers (CTs)

4.8.1 General

Insulation of current transformers shall be of epoxy resin or butyl rubber moulded typeand shall have the same insulation level as the switchgear. The transformers shallcomply with the requirements stated in IEC 60044 or equivalent AS. The accuracy classshall be Class 1 for metering CTs as per IEC 60044 or equivalent AS. The accuracyclass for protection CTs shall be 5P20 as per IEC 60044 or equivalent AS. Vendor shallprovide CTs with better accuracy class where required for specific applications

The current transformers shall be suitable for withstanding the stresses corresponding to

the thermal and dynamic short-circuit currents imposed on the electrical system for thetime rating of the Switchgear.

All current transformers shall have rating as shown on the single line diagram. TheVendor shall state the ratio, burden and accuracy class of all CTs.

CT secondaries shall be provided with shorting links facility.

Current transformers used for unit protection system, shall be similar in characteristics atboth ends of the system, and shall be selected in accordance with the relaymanufacturer's recommendations.

4.8.2 CTs for Differential Protection

Vendor shall mount one set of the CTs in the HV switchgear and shall supply the secondset loose for installation on the protected equipment (e.g. generator, motor, transformer).Purchaser will supply information regarding the mounting details, diameter of the CTsetc. for the equipment end, required by the Vendor, after placement of the order.

4.9 Trip Circuit Supervision

Trip circuit supervision relays along with indicating LEDs shall be provided for all circuitbreakers and contactor starters/feeders.

4.10 Protective Relays

4.10.1 General

The HV switching devices shall be equipped with the type of protection indicated on thesingle-line diagram.

Protective relays shall be flush mounted draw-out type preferably with built-in testfacilities.

Any protective relays without built-in test facilities shall be provided with separate testterminal blocks mounted on the front panel of the switchgear.


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Each protective relay shall be fitted with a flag indicator, which can be reset externally.

Under-voltage relays shall be fed from potential transformer located in the bus sectionand shall be wired to the trip circuit of the motor starters. The under-voltage circuit shallnot be connected to lockout relays.

All incomers and feeders shall be provided with micro processor based protection relays.

4.10.2 Protective Relay Co-ordination

If specified, vendor shall provide recommended settings for each of the relay beingsupplied as part of HV Switchgear, based on the following information to be supplied to

Vendor after placement of order:

(i) Maximum and minimum fault level

(ii) Information on Transformer

(iii) Information on time current characteristics of downstream LV Switchgear/MCCprotections.

Vendor shall request all relevant system information and information for downstream LVsystem required by Vendor for protective relay co-ordination.

Vendor shall provide complete calculations and graphs showing time current

characteristics of relays for recommended settings to show how co-ordination has beenachieved. The co-ordination gaps shall be clearly visible on all graphs.

4.10.3 Relay Programming

Vendor shall supply all relays pre-programmed (for required outputs, inputs, logic etc)and set to work in accordance with the settings calculated. Vendor shall test protectionsettings at Vendors works. In addition Vendor shall supply the required software fordown loading of all required settings to all relays.

Prior to commencement of construction Vendor shall submit details of the relayprogramming together with detailed drawings of the switchgear for approval by

Purchaser.

4.11 Instruments

The instruments shall be flush mounted, taut band switchboard type, and wide anglewith a scale deflection not less than 240 back connected and with an accuracy of 1.5%of Full Scale Deflection. An external zero adjustment shall be provided.

Watt-hour meters shall have cyclometric registers and shall normally be of 2-elementtype.

The requirements for instruments shall be as shown on the single-line diagrams.


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Ammeter scales shall indicate full-load current at approximately 60% of full scale.

4.12 Auxiliary Switches, Devices and Wiring

Internal wiring (excluding main HV power circuits) shall be moisture resistant PVC, 600Vgrade, flexible, tinned copper stranded type conductor (minimum 30 strands is required).The wiring shall be flame retardant to IEC 60332-1.

Conductor ends shall be fitted with a crimped termination device with an insulatedshank. When more than two conductors need to be connected together, terminals whichutilise permanent solid links, shall be provided.

Terminals for different AC voltages shall be separated from each other using barriersand completely segregated from DC circuits. All terminals on door mounted equipment /devices that normally remain energised when the circuit breaker is withdrawn shall befully shrouded. Terminals for connection of 240V AC and above shall also be shrouded.

Wiring terminal blocks shall be arranged and positioned to afford easy access forcabling, testing, inspection and maintenance. For current and voltage transformersecondary circuits, terminals with facilities for measuring, isolating or short circuiting asnecessary shall be provided.

Each switchgear cubicle shall be equipped with an anti-condensation heater, a manualcontrol switch and a pilot LED with identifiable indication. All internal heaters andthermostats shall be completely internally wired

A separate DC control power bus, complete with terminals for an incoming feeder, shallbe furnished for each bus section.

Each panel shall be equipped with the following indication LEDs:

Circuit breaker closed: Red

Circuit breaker open: Green

Trip circuit healthy: White

Fault trip: Amber

DC Failure: Blue

Separate circuit breakers (MCBs) shall be provided for control power for each unit.Tripping of control circuit MCB shall be annunciated as a fault.

Fuses and/or MCBs shall be used for protecting voltage circuits of metering supplies andauxiliary equipment e.g. space heaters.

The minimum size of control wiring shall be 1.5mm except for CT secondaries, whichshall have 2.5mm wiring.


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Internal wiring shall be run in ducts to facilitate safe insertion and removal of individualwires.

The inter-panel wiring shall be terminated on terminal blocks at shipping breaks.

Local trip buttons located on switchgear shall operate independent of remote tripbuttons.

All internal wiring shall be ferruled with the respective wire number, clearly and durablymarked in black on the white background.

4.13 Terminals

The switchgear shall be equipped with a set of relays for remote annunciation of faults.

The switchgear shall be supplied complete with an air insulated main power cable-terminating compartment.

Removable un-drilled brass gland plates of a minimum thickness of 5mm shall beprovided for both power and control cables. Terminal blocks shall be placed at least200mm away from gland plates.

Klippon or similar terminal blocks shall be supplied for outgoing control cableterminations. The outgoing cable terminal blocks shall have the Vendor's standard wire

numbering on the equipment side of the terminal block and the incoming cable and corenumbers on the outgoing side of the block. Shrouded terminals shall be provided for240V and above AC connections. Terminals of different voltages shall be segregated.

Terminals for power cable shall be sized for the cable specified on the Data Sheets andsingle-line diagrams. All other terminals shall be sized for 2 x 2.5mm.

Vendor shall furnish all terminals including 20% extra terminals as spare.

5 ACCESSORIES

The switchgear shall include the following accessories as a minimum:

Lifting lugs

Touch-up paint

Standard accessories and special tools.

A complete set of standard accessories for the switchgear, including test jumpers, testrack and a set of special tools necessary for the erection, commissioning, maintenance,and operation shall be provided. They shall be contained in a suitable box or containerwith locking facility.


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5.1 DC Power

The DC Power System shall be 24V DC unless stated otherwise on the Data Sheets.The DC power supply system shall consist of:

One (1) battery charger

One (1) battery bank

One (1) DC distribution board.

Battery charger shall be capable of supplying the maximum load that can occur on theDC system (e.g. spring charging of circuit breakers and contactors after tripping of all ofthem, maximum simultaneous tripping load and additional 20% spare capacity) inaddition to the boost (equalising) charging of the battery bank.

Battery charger shall be equipped with set of contacts for remote alarm charger failure.

Recharged battery shall maintain the system during mains power supply failure for aminimum duration of 1 hours at maximum loading of controls and indications.

Battery shall be sized to adequately satisfy switchgear requirements with 20% sparecapacity.

The module-isolating switch for battery and battery charger shall be a miniature circuitbreaker. The front panel of battery charger shall be fitted with two indicator LEDs andan analogue meter scaled to read DC output volts. One LED shall indicate primarycircuit healthy and the second LED shall indicate battery charger failure.

5.2 Marking and Finishing

5.2.1 Nameplates / Labels

Machine engraved nameplates/labels with full text shall be installed to designate thepurpose of all circuits, instruments, meters, relays and fuses. Circuit identificationnameplates/labels shall be labels on the back as well as on the front of eachcompartment. All nameplates / labels shall be adjacent to the devices and not mounted

directly on the devices. All labels shall be of non-corrodible type, engraved or printed inEnglish, and shall be of sufficient size to provide easy reading from normal operatingand maintenance positions.

Nameplates/labels shall be manufactured from laminated plastic, showing black letteringon a white background.

Each cubicle on the switchgear shall have labels on doors, switches, shutters, or wherenecessary to caution, warn, or indicate safety precautions, and any other informationdeemed necessary for personnel protection.


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Nameplates shall be securely mounted with machine screws such that they may beeasily changed or replaced.

Labels shall be securely fixed to the equipment using not less than two fastenings bolts.Nuts and washes shall be zinc or cadmium plated. Fastenings shall not loosen due tovibration.

The main switchboard labels with switchboard details shall be mounted using bolts nutsand washers as per specification. All other labels such as for individual drives etc. shallbe mounted using adhesives.

Warning and danger labels shall have red lettering on a white background.

5.2.2 Finish

All metal parts shall be protected from rust and corrosion by plating or painting. Paintedparts shall be to Vendor standard painting procedure.

Vendor shall submit painting specifications and procedure to the purchaser for approval.

All other parts, such as handles, levers, and fasteners that are not stainless steel shallbe cadmium, nickel or chrome-plated.

A minimum of 300 ml can of matching touch-up paint shall be furnished with each three-

(3) vertical sections of switchboard cubicle line-up or fraction thereof.

The fully assembled panels shall be mould and vermin-proof and shall be treated toprovide a lasting durability under the specified service conditions.

5.2.3 Site Storage

A set of recommendations, based on the project environmental conditions and detailingmeasures to preserve the quality/integrity of the switchgear during a 12 months sitestorage in the open, shall be provided by the Vendor.

5.2.4 Erection and Special Tools

Special tools and equipment, including circuit-breaker-handling trolley's if they arerequired, for erection, commissioning, maintenance and testing shall form part of theorder and be shipped together with the assembly.

5.3 Inspection and Testing

The switchgear shall be fully assembled, wired and tested at the factory and subjected torigorous QA and testing at all stages of manufacture.

The tests shall be carried out by the Vendor at his works, in accordance with relevantStandards in Section 2 and the requirements of this specification, unless agreedotherwise.


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All formal testing will be conducted in accordance with a written test procedure. TheVendors test procedures shall be submitted to the Purchaser prior to the factoryacceptance test for approval. Each formal acceptance test must be signed by theVendors and the Purchasers representatives at the successful completion of the test.

The Vendor shall ensure that adequate notice (a minimum of 15 working days) is givenin writing to the Purchaser prior to the factory acceptance testing.

The Vendor shall afford full facilities to the Inspector during the course of manufactureand shall arrange access to any Sub-vendors works where necessary. Details of thisrequirement shall be resolved in pre-inspection meetings.

The acceptance of the work by the Inspector and its release for shipment shall in no wayrelieve the Vendor from any responsibility for carrying out all of the provisions of thisspecification and relevant documentation, nor does the Purchaser, by such approval andrelease, assume any responsibility for such provisions.

All test and inspection data shall be legible, including the name and signature of theVendor and, where applicable, the Inspector.

All defects in materials detected during testing shall be repaired or replaced by theVendor at no cost to the Purchaser. If the correction of any error or defect involvesserious alterations requiring replacement of parts, the approval of the Purchaser shall beobtained before proceeding. If the correction of the error requires witnessing by theInspector, the Inspector shall sign the correction. Retesting of repaired or replacedmaterials shall be mandatory.

If any part of the equipment is damaged after tests have been completed, retesting ofthe affected parts is mandatory. The method of repair shall be in accordance with theVendors standard procedures and approval of the Purchaser.

The Vendor shall supply supervision, specialist personnel and all necessary materials tosupport the inspection and testing.

All test equipment shall be in good working condition and shall have been calibrated byan endorsed laboratory. Copies of calibration certificates shall be provided to thepurchaser prior to the commencement of testing.

Testing shall be carried out by the Vendor and will be witnessed by the Purchaser or hisnominated Inspector at various stages of manufacture and assembly.

5.4 Factory Acceptance Testing (FAT)

The FAT shall be conducted in accordance with the Vendors standard QA procedures.The Vendors standard procedures shall be submitted to the purchaser at least two (2)months prior to testing for approval.


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PROJECT

CONTRACTOR


SWITCHGEAR


The Vendor shall be responsible for generating the FAT procedures. A 100% correctperformance is required. The scope and manner of routine testing shall be inaccordance with IEC 60298.

The FAT shall include as a minimum the following:

Visual inspection to prove conformity with the approved drawings and the order.

Spot checks to verify the degree of protection; reliability of operating mechanisms,

interlocks and safety features; insulation levels; creepage distances; earthing;labelling and interchangeability.

Main and auxiliary cable circuits checked against approved schematic circuitdiagrams.

Insulation resistance tests.

Ductor testing of all bus-bar connections.

Dielectric tests on all main, control and auxiliary circuits.

Primary and secondary injection tests.

Phase sequence and polarity tests

Full functional testing of circuits for correct mechanical and electrical operation,

including the operation of their control, communications, interlocking, alarming andprotective devices.

Following the above tests, the switchgear and their components shall be examined forany damage and to ensure that all parts are in satisfactory operating condition.

Complete records of the above inspection and tests shall be compiled into oneinspection document by the Vendor.

On completion of the FAT the switchgear shall be checked and shipped to thenominated destination.

5.5 Certificates of Acceptance

On satisfactory completion of the FAT, the Vendor shall provide an appropriatecertificate of equipment acceptance.

Attached to these certificates shall be all test records and other relevant documentation.These shall form part of the Manufacturers Data Report (MDR).

The Purchaser will review and approve these certificates.

Final acceptance of the Switchgear/MCC shall be on satisfactory completion of theWarranty period.

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