unsw energy management · natural gas flow meter area classification sheet 34 ... unsw meter data...

11/12/2012

I:\EDFO\FM\Asset Management\Energy Management\06. D&C REQUIREMENTS\Drafts\UNSW ENERGY MANAGEMENT METERING REV3.2.docx

UNSW ENERGY MANAGEMENT DESIGN AND CONSTRUCTION REQUIREMENTS

INSTALLATION OF GAS, ELECTRICITY AND WATER METERS

INDEX PAGE

INTRODUCTION 1

DOCUMENTATION, APPROVALS AND CHECKLISTS 1

COMMUNICATIONS NETWORK 2

ELECTRICAL METERS 4

WATER METERS 7

GAS METERS 8

ANNEXURE 1: METER CONNECTION SCHEMATICS 13

ANNEXURE 2: ELECTRICAL METER WIRING DIAGRAM 16

ANNEXURE 3: ELECTRICITY METER INSTALLATION CHECKLIST 18

ANNEXURE 4: WATER METER INSTALLATION CHECKLIST 21

ANNEXURE 5: GAS METER INSTALLATION CHECKLIST 24

ANNEXURE 6: TYPICAL INTRINSIC SAFE BARRIER RELAY BOX ARRANGMENT 27

ANNEXURE 7: HAZARDOUS AREA REPORT 28

DETERMINING A HAZARDOUS AREA FLOWCHART 32

NATURAL GAS FLOW METER AREA CLASSIFICATION SHEET 34

EXAMPLE OF AREA CLASSIFICATION FOR GAS FLOW METER 35

EXAMPLE FLAMMABLE MATERIAL LIST 36

EXAMPLE SOURCE OF RELEASE LIST 37

AS/NZS60079.10:2004 EXAMPLE OF SOURCES OF RELEASE 38

ANNEXURE 8.1: ELECTRICITY METER DATA FORM 39

ANNEXURE 8.2: GAS METER FORM 40

ANNEXURE 8.3: WATER METER DATA FORM 41

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UNSW ENERGY MANAGEMENT DESIGN AND CONSTRUCTION REQUIREMENTS INSTALLATION OF GAS, ELECTRICITY AND WATER METERS INTRODUCTION The university has an extensive campus-wide Energy Monitoring and Control System (EMAC System) comprising of digital electrical meters, and water meters and gas meters with pulse outputs. They are remotely monitored via a communications network. The EMAC System measures consumption of utilities such as electricity, gas and water. Information from these meters can then be used to set up trends; determine flow rates; generate alarms; and send data to another software program to determine billing. Metering for electricity, gas and/or water consumption will generally be required for new buildings and/or major plant items, specified services or user groups. This section of the D&C manual covers the following topics:

1. Documentation, Approvals and Checklists 2. Communications Network 3. Electrical Meters 4. Water Meters 5. Gas Meters

This section of the D&C applies not only to new installations but also to any replacement or relocation of meters. It also places documentation obligations on any person who knowingly makes significantly changes to the load monitored by a particular meter. Tenderers and Contractors are required to clearly demonstrate how they are able to incorporate meters into the EMAC System in a way that will provide full functionality and remote monitoring. The notes that follow outline minimum technical requirements that need to be incorporated into any proposal to supply and install meters at UNSW. The final step in the integration of a new meter into the system involves software tasks within the EMAC program itself. This work is undertaken by UNSW in-house or by a Contractor specifically assigned to this task by UNSW (EMAC software support company). This final step does not fall within the scope of work for meter installation covered by these D&C requirements. DOCUMENTATION, APPROVALS AND CHECKLISTS The location and type of every meter planned for installation at UNSW must receive approval from the UNSW Energy Manager prior to any associated work commencing. To receive approval, to enable the meter to receive proper documentation and to facilitate connection of the meter to the EMAC System, the Contractor must fill out the standard UNSW Meter Data Form and forward it to the Energy Manager prior to any work starting. A separate form shall be filled out for each meter and there is a different form for electrical,

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water and gas meters. The required information to be completed on these forms includes the meter type and model; the exact meter location and a description of its load. In addition to completely new meter installations, a Meter Data Form must be filled out whenever an existing meter is replaced. A form must also be filled out when a meter is shifted. Finally, for completeness, a form is required when the load on a meter changes substantially. Any person who knowingly alters a utility network (pipes, cabling, DBs etc) so that the load downstream of a meter changes substantially, should advise the Energy Manager in advance by filling out the relevant meter form. Blank copies of the meter forms for electricity, gas and water are in Annexure 8. When the meter form is received and the installation approved, a unique identification number is given to each individual meter by the UNSW Energy Unit. This enables accurate tracking of each meter as well as identifying this meter on the EMAC System. The approval and documentation process is as follows:

1. The contractor fills out the relevant sections of the Meter Data form and forwards it to the UNSW Energy Manager;

2. The Energy Manager will approve/decline the proposal, assign a meter number and

return the form to the potential installer;

3. The meter is installed in accordance with the UNSW Meter D&C and any special conditions noted by the Energy Manager on the Meter Data Form;

4. When the installation is complete the installer advises the Energy Unit by email -

[email protected] - and provides some additional information, such as, the initial meter reading and the meter serial number.

After the installation is complete the Contractor shall also supply an individual calibration certificate for each meter. Each existing electricity meter appears on an electrical layout drawing; each existing water meter appears on a water layout drawing; and each existing gas meter appears on a gas layout drawing. Whenever a new electrical, water or gas meter is installed, the Contractor shall update the relevant drawing. To assist contractors with carrying out meter installations a checklist has been prepared for each meter type. The checklists are presented in Annexes 2, 3, 4. COMMUNICATIONS NETWORK

The EMAC System has been configured using the CitectSCADA proprietary software and Microsoft SQL Server. The EMACS system utilises the UNSW's Ethernet Network infrastructure (via Virtual LAN) to communicate with Electricity, Gas and Water Meters distributed throughout the Kensington Campus.

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The communication protocol between the EMACS and the meters is Modbus/TCP via a device called a Modbus to Ethernet Bridge (or ETG). This device allows the conversion between the Modbus (serial) protocol and Modbus/TCP (Ethernet) protocol. The Modbus to Ethernet Bridge devices shall be configured to operate at 9600 baud. The preferred Modbus to Ethernet Bridge to be used at UNSW is the ConneXium TSXETG100 Gateway by Schneider Electrics. Electricity meters and PLCs are connected by a localised Modbus (RS485) network in a daisy chain configuration. The last device connected to the daisy chain shall have a 120ohm terminating resistor connected across its communication terminals. The maximum number of Modbus capable meters and PLCs connected to the same RS485 network shall be limited to 20 and the overall cable distance shall be limited to a maximum of 1200m. In an ideal installation, the number of meters and the maximum distance of the cable chain that the Modbus network can handle is more, but due to the environment in which the meters are located (switchrooms and sub-stations) the design shall be conservative. Several Modbus networks have been setup at various points around the Campus; mainly at locations where there are clusters of electrical meters and PLCs. Each electrical meter or PLC must have a unique Modbus address to allow the EMAC System to identify the device. Note. Gas and Water meters are connected to the Modbus network indirectly via PLCs or PQM Meters. Each localised Modbus Network is connected to a Modbus to Ethernet Bridge; which is connected to a LAN port that has been configured for the EMACS VLAN. This LAN port configuration must be carried out by UNSW IT Services department. It is not possible to access the VLAN and the EMACS servers otherwise. Each Modbus to Ethernet Bridge is configured with a unique IP address. To enable their communication over the VLAN, new bridges shall have IP addresses which are allocated by UNSW. Where the requirement for Modbus connections is greater than 20, then extra Modbus to Ethernet Bridges shall be used. This does not preclude the Contractor from proposing an alternative connection method, which shall be presented to the Energy Manager for approval before installation commences. The best way to install a new EMAC integrated electrical, water or gas meter will depend upon a number of factors. These include the quantity of meters; the location of the meters; the proximity to an existing Modbus network that is not already over-populated; proximity to a LAN port; available space to mount panels; etc. The notes below on the choice of electrical meter give some indication of the type of consideration. The Contractor shall issue their communication connection plan to the UNSW Energy Manager during the design process and before construction proceeds. Where a new PLC is used to connect water or gas meters to the EMACS Communication Network, the UNSW standard software program shall be downloaded into the PLC. The only variable to the standard software is, as previously mentioned, that the PLC must have its address changed to a unique one. This address is nominated by UNSW.

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All new PLC’s shall be Schneider Twido PLC’s that come with 14 digital inputs and 10 outputs as standard. The part number for the PLC is TWDLCAA24DRF and they require a 240VAC power supply. Communications is via the installation of an optional RS485 card, with part number TWDNAC485T. If analogue signals are required, then an additional analogue input card (part number TWDAMI8HT) shall be attached to the Twido PLC. Each new communication network shall have a Block Diagram drawing showing the communication paths as per the example UN01-UNW_DWG003. ELECTRICAL METERS All new electrical Digital Power Meters (DPM) shall be selected from the following list or equal and approved by the UNSW Energy Manager:

Manufacturer Model Part No.

Schneider ION 6200 ION6200-A0A0B0A0B0R

Schneider PM 5350 PM5350 (four input module)

Schneider PM 850 PM850MG

Schneider ION 7650 M7650A0C0B5E0A0E

Generally, the preferred option for standard applications is the ION 6200 meter, especially when there are no water or gas meters to be connected. The PM5350 meter comes equipped with four pulse inputs, ideal for connecting a limited number of water or gas meters that are in the immediate vicinity. Which particular meter shall be installed will depend upon the requirements of the installation or project. In the case when there are water or gas meters to be connected, the ION 6200 can still be used in conjunction with a Telemecanique Twido PLC. The PLC can handle up to 14 pulse inputs. PM 850 meters shall be used as main meters in substations and when power quality monitoring is required, while ION 7650 meters shall be used on the HV feeders at campus level. The meters identified above incorporate “on-board” memory retention capability in the event of power failure. All meters shall have an RS485 serial communication output (or Ethernet output) and communicate using the Modbus TRU network protocol. Meters shall monitor either single or three phase loads and shall display and communicate (for each phase and in total) the following parameters:

Phase and Line Voltage (VL-N, VL-L) Accuracy 0.5% of reading

Current (A) Accuracy 0.5% of reading

Frequency (HZ) Accuracy 0.1% of reading

Power (W, VA and VAr) Accuracy 1.0% of reading

Power Factor (lead/lag) Accuracy 1.0% of reading

Energy (kWhr) Accuracy 1.0% of reading

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Demand (max/min kVA) Accuracy 1.0% of reading

THD For PM 850

THD and Individual Harmonics For ION 7650

In the case of the ION6200 the following Demand Calculation parameters are also required to be configured in the meter:

1. Demand Calculation Type: Not-configurable. Both Sliding Window and Thermal Exponential Calculations are available. The EMACS uses the Sliding Window Calculation.

2. Demand Sub-Period: Configurable. Set to 3 minutes. 3. No of Demand Sub-Periods: Configurable. Set to 5.

All meters shall be installed together with approved terminal strips for data cables (where required), CT wiring and shorting links, power supplies, fuses or circuit breakers. The following sections shall also be adhered to. Please refer to standard UNSW drawing CTM-E01/2 in Annexure 1. Construction–General

1. All current transformer circuit wiring shall be 2.5mm2, unless otherwise specified by N.S.W service (S.I) rules.

2. Where potential circuit wiring is unprotected from the busbars to the NS type fuse assemblies, the minimum conductor size shall be 4mm2 SDI or clear sheathed cables, with phase colour identification. The cabling length must be less than 500mm.

3. The potential circuit wiring shall be 2.5mm2 from NS fuse assemblies in phase insulation colour where single conductors are used. In the case of a multicore cable, individual wire numbers representing the core number shall be clearly marked using an approved numbering system.

4. The potential fuses at the switchboard shall be accessible without the need for switchboard isolation.

5. The CT’s shall be shorted using the standard shorting terminals on the meter connection side when the cables to the meter panel are not yet provided.

6. Conductor numbering shall use the project design numbering system where provided. If not provided, the conductor shall be identified as per drawing CTM-E01/2.

7. Consideration shall be given to the installation of CT’s, switchboard shorting links and the associated cabling ahead of time if there is potential for future metering requirements.

8. Communication cables and switch input cables to DPM’s shall be segregated from all CT and potential supply cabling.

9. Where DPM’s are to be installed, the electrical Contractor shall provide and install the CT’s, switchboard shorting links, potential fuses, neutral link, earthing and associated cabling.

10. Generally, meters, meter panel and the wiring from the switchboard CT shorting links to the meter panel shall be by UNSW or an approved Contractor.

11. All wiring and installation shall be to the current Australian Standards. Current Transformer

1. All current transformers (CTs) must be provided with 5A secondaries to comply with the UNSW Installation Standard.

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2. From each of the two CT secondary terminals, a cable shall be run to the EMACS metering panel shortening links, ie. 2 cables from each CT. (as per diagram)

3. CT’s toAS60044-1 2003, 5VA class 1.0 up to 400/5, 15VA class 1.05 200/5 and above.

4. CT bar primaries shall be 450mm in min length and of removable link construction type for major busbars of Main Switchboards. For smaller DB metering removable links are not required.

5. CT bar primaries shall be fully contained in one chamber. 6. CT ratio to be visible on at least one CT of a matched set.

Phoenix Meter Pan, CT Shorting Links and Potential Fuses The terminals, fuses, & fuse assemblies shall be specified as per the table below:

CT SHORTING LINKS AND POTENTIAL FUSES PARTS LIST

SWITCHBOARD (WAGO BRAND)

PART No.

METER PANEL (PHOENIX BRAND)

PART No.

3x Series 282 End Plates 282-387 2x Clipfix 35-5 End Brackets 3022276

6x Disconnect/Test

Terminal Blocks

282-870 4x UK 5 – HESI Fuse Term Block

3004100

3x Series 282 Jumpers, Orange

282-424 5x UDK4 Plain Terminal

2775016

3x Series 282 Locking Covers

282-882 6x UDK4-MKT-P/P

Knife Disconnect

2775210

Din Rail NS 35/7.5

Length to Suit NRA-35-1

3x URTK/S-BEN 10

Slide Terminals

0309109

3x NS Fuse Assem

Sage Clip Style

Din Rail NS 35/7.5

Length to Suit

0801733

(Shrouded Contacts

(MEM, GEC or Glass Tube Fuses

Front Wired) ALLSTOM) 8x 5x30mm Type F

3x4 AMP HRC Fuses

See Table for Details

Note: Spare fuse to be provided in each carrier Labelling

1. The location of the CT’s shall be labelled on the enclosure exterior. 2. CT’s circuit designation shall be identified. 3. Labelling shall be engraved traffolyte W-B-W secured using non-metallic rivets or

fasteners. 4. The CT shorting links shall be labelled with

(a) Circuit designation (b) CT’s shorted (c) CT’s normal.

A checklist has been provided to assist both the UNSW Facilities Engineer and the Contractor to ensure that the important steps have been completed and signed off on. Please refer to Annexure 2.

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POTABLE AND BORE WATER METERS: The Davies Shepherd (Elster Metering Pty. Ltd.) with pulse attachment suitable for connection to the UNSW EMAC System shall be used for general purpose metering at UNSW. The water consumption of all buildings shall be metered. In addition, sub-meters shall be installed on all water consuming plant and equipment or sub-uses (DHW make up) that are likely to use more than 20% of the total building Average Daily Demand. Sub-metering is also important for any major plant where noting changes in water consumption assists with diagnosing performance, or detecting leaks and breakdowns. Examples of where metering may be included are: cooling towers, laboratory non-potable water, irrigation, toilet flushing tanks and pure water treatment plants. The pulse attachment consists of a magnetic reed switch that closes a dry contact (voltage free) every time a certain amount of water is passed through the meter. The amount of litres per pulse can vary depending upon the size of the water pipe and the proposed water usage. The design flow of the water meter shall be for normal average use and not for maximum demand. Typical values are 5L/pulse; 10L/pulse and 100L/pulse. The smaller the volume per pulse, the higher the resolution of the information for billing purposes is as well as the more accurate a flow rate can be determined within the EMAC system. However, the most accurate way of determining flow rate is by using a flow meter that is connected to the EMAC system through an analogue input card of a PLC. Another useful signal that can be displayed on the EMAC System is water pressure. Being an analogue signal it also shall be connected to an analogue input card of a PLC, a PQM meter shall not be used. The necessary modifications shall be carried out to the PLC programme to allow the monitoring of the analogue inputs by the EMAC System. To install a pulse attachment to the EMAC System the point of connection to the EMAC System shall be determined. There are two methods that are normally used throughout the Campus. The first deals with finding the nearest PQM electrical meter that has spare auxiliary pulse input and the second deals with finding the nearest PLC that has a spare digital input. However, if the cost of cabling to the nearest PQM or PLC becomes excessive, a third alternative is to install a new PLC with an Ethernet/Modbus bridge in a panel mounted near a LAN port. After the connection point has been determined, a 1 or 2 pair twisted cable shall be run from the PQM or PLC to the water pulse attachment. Care shall be taken that there is enough mechanical protection for this cable along its complete length, especially when the water meters are installed in garden beds. The water pulse attachment normally comes with a small length of 2C or 4C cable. The two cables shall be connected together in a small weatherproof junction box. The pulse quantity signals shall be verified by taking a manual reading of the analogue water meter and then re-checking it after sufficient water has passed through the meter, e.g. say after a week. The difference in the meter reading should correlate to the amount shown on the EMAC System. This should hence provide clarification of the actual quantity per pulse to be used on the EMAC System. A checklist has been provided to assist both the UNSW Facilities Engineer and the Contractor to ensure that the important steps have been completed and signed off on. Please refer to Annexure 3.

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GAS METERS: Diaphragm meters shall be used for all purposes across the Campus due to their accuracy, minimal maintenance and turndown ratios up to 600:1. Turbine meters shall not be used due to their small turndown ratio and rotary meters shall not be used due to their on-going maintenance requirements. Refer to Table 1 on the next page. Where special circumstances arise that make it difficult to install a diaphragm meter then an alternative type can be proposed to the Energy Manager, but shall be approved before being installed. Meters shall be sized for normal demand rather than maximum demand possible to ensure that small losses are identified. Where a medium pressure supply (100kPa) exists, special meters shall be correctly sized by the meter supplier for the given pressure. As a guide, based on Ampy+Email meters, the gas flow model relationship is as follows:

Model 750 – up to 7.5m3

/ hour

AL 425 – up to 12m3

/ hour

AL 800 – 0.1 to 22m3

/ hour

AL 1000 – 0.1 to 28m3

/ hour

AL 1400 – 0.1 to 40m3

/ hour Each building shall be provided with a pulse type gas meter. Sub-meters shall also be installed on all major gas consuming plant and equipment which is likely to use more than 20% of the total building Average Daily Demand, and any location where inefficiencies and losses are potentially a problem. The meters shall be fitted with pulse attachment suitable for connection to the UNSW EMAC System. This shall consist of a dry contact (voltage free) that closes every time a certain amount of gas is passed through the meter, thus allowing the quantification of gas consumption. Gas is measured in meters cubed, and the calculated energy consumption is provided via the EMAC system. The volume per pulse can vary depending upon the size of the gas pipe and the proposed gas usage. Typical values are 0.01 pulses/m3; 0.1 pulses/m3

and 1 pulses/m3. The smaller the volume per pulse, the higher the resolution of the information for billing purposes is as well as the more accurate a flow rate can be determined within the EMAC system. However, in special cases where more accurate flow rates are required, as opposed to quantities, then an analogue flow meter shall be used. Meters shall also be fitted with automatic temperature and pressure correction equipment. Where this is considered to be excessive for the particular installation, then approval shall be sought from the Energy Manager to ignore. Where automatic temperature and pressure correction equipment is not used, then the inlet gas pressure in kPa shall be supplied with the other required documentation mentioned previously. The Contractor shall provide the assembly with an upstream filter and regulator to stabilise inlet pressure and downstream regulator with discharge pressure to suit the equipment connected. A pressure test point shall also be provided after the regulator on both the inlet and outlet sides of the meter.

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Table 1: Factors Affecting Gas Meter Selection

The following table details the factors affecting gas meter selection:

Factors Diaphragm

Meters Rotary Meters Turbine Meters

Typical Range At least 600:1 at +/-

1.5% At least 20:1 to 90:1

50:1 extending with increase in density

Maintenance Not required

Bi-annual or annual inspection of oil level.

Refer to manufacturers recommendations.

Annual inspection (spin test) of turbine blades. Refer to manufacturers

recommendations

Continuity of supply

Meter failure can interrupt gas supply.

Meter failure has virtually no effect but meter will

not register.

Gas borne Solids Normally unaffected. Meter failure will

interrupt the gas supply. Filter required.

Blades may be damaged and freedom of rotation may be affected. Filter

required.

Flow Variations Generally unaffected

Owing to inertia of impellers sudden and large changes in flow

can lead to momentary high or low downstream

pressures.

Owing to inertia of turbine rapid cyclic flow-registration. Effect will depend on frequency and magnitude of flow

changes.

Presence of Liquids

Corrosion possible. Freezing can stop meter and cause permanent damage. Material of construction may be

affected.

Corrosion possible. Oil may be displaced from

gears. Freezing possible. Materials of construction

may be affected.

Corrosion possible. Freezing possible.

Lubricant dilution and rotor imbalance are

possible. Materials of construction may be

affected.

Gas Density

Unaffected in design range within

manufacturer’s specifications.

Insignificant. Minimum flow is lowered with increased density.

Pressure Variations.

Excessive differential pressure variations will

cause damage.

Rapid change of differential pressure may

cause damage.

Rapid pressure changes may cause damage.

Particular problems when meters are installed at

high pressure.

Accommodating Future Demand

Increase in maximum flow needs larger meter or additional streams or higher pressures. Initial over-sizing may affect low flow measurement accuracy.

Operating Pressure

Typically less than 10 kPa. Special version up to

700 kPa available.

Available up to ANSI 150 (20 Bar).

Available up to ANSI 600.

Pipe Work Requirements

Large physical volume for give rating. No special

pipe work considerations. Bypass may be required.

No special pipe work considerations. Filter

may be required. Bypass may be required.

Straight pipe length at inlet of meter required upstream of the meter (or flow straighteners

utilised). Flow restrictors may be installed to

prevent turbine over-speeding. Filter may be required. Bypass may be

required.

Meters shall be housed within a weatherproof enclosure where installed outside of buildings.

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A checklist has been provided to assist both the UNSW Facilities Engineer and the Contractor to ensure that the important steps have been completed and signed off on. Please refer to Annexure 4. All gas installations, including gas metering, are required to be classified as either being hazardous or non-hazardous by a UNSW representative. This classification indicates to what level of protection is required during the installation and the equipment used in the installation. The methodology to determine the classification can be found in Annexure 6. Whether a hazardous or non-hazardous installation, to connect a gas pulse output to the EMAC System the point of attachment to the EMAC System shall be determined. There are two methods that are normally used throughout the Campus. The first deals with finding the nearest PQM electrical meter that has spare auxiliary pulse input and the second deals with finding the nearest PLC that has spare digital input. However, if the cost of cabling to the nearest PQM or PLC becomes excessive, a third alternative is to install a new PLC with an Ethernet/Modbus bridge in a panel mounted near a LAN port. Non-Hazardous Installation Requirement If the gas meter and the area in the vicinity of the gas meter are deemed non-hazardous then the meter’s pulse attachment connection is straight forward. The pulse attachment normally comes with a small length of 2C or 4C cable and therefore a small junction box mounted alongside the gas meter is required. The pulse attachment cable shall be connected inside this j-box to the 1 or 2 pr twisted cable that is run from the PQM or PLC. Hazardous Installation Requirement If the gas meter and the area in the vicinity of the gas meter are deemed hazardous then the meter’s pulse attachment connection is a little more complicated. After the meter’s connection point to the EMACS Communication Network has been determined, a 1 or 2 pair twisted cable shall be run from the PQM or PLC to the gas meter’s Intrinsically Safe (IS) Barrier. The IS Barrier shall be mounted in a standard junction box in a suitable location as per the UNSW standard drawing CTM-E05/2 found in Annexure 5. The cable is connected to the output relay contact of the IS Barrier Relay. The gas meter pulse attachment output normally comes with a small length of 2C or 4C cable. A small junction box shall be mounted locally to the gas meter to provide a connection point for the meter pulse output cable to the IS cable that runs back to the IS Barrier. This cable connection shall be done using a resistor configuration that utilises the IS Barrier’s fault detection function. The resistors enable short circuit and open circuit detection by the IS Barrier allowing alarm generation. The cabling from the IS Barrier to the gas meter shall be identifiable as an IS installation, preferably using blue coloured dekoron cable. This cable is then connected to the input of the IS Relay. Care shall be taken that there is enough mechanical protection for all cables along their complete length. Testing the Installation To test actual quantities for these signals, take a manual reading of the analogue meter and re-check after say a week’s usage of gas. The difference in the meter reading should

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correlate to the amount shown on the EMAC System. This should hence provide clarification of the actual quantity per pulse to be used. Gas quantities are measured as a volume and then converted into an energy consumption using average heating values and pressure correction factors. Equipment Construction for IS Barriers The following details shall be used as a guide:

1. Enclosure:-

Clear lid PVC 220mm x 170mm x 80mm (ABB or Square D) 2A din rail mount 6kA (minimum) circuit breaker 4 pole PVC circuit breaker enclosure (Hager) 1 pole PVC circuit breaker enclosure (Hager) Din mounting rail 1 or 2 intrinsic safety barriers relay(s) dual channel (solid state)

24VDC type KFD2-SOT2-EX2 Grounding terminal block WK 4 SL/U (for up to 2.5mm2)

2. Conduits:- Conduits shall be terminated using conduit adapter in ISB enclosure

maintaining IP65. 3. Cabling:-

240VAC wiring shall be fully enclosed within 4 pole Circuit Breaker enclosure

Hazardous area cable dekoron instrumentation cable shall be used (preferably blue in colour)

Hazardous area cables shall be confined to area labelled “Hazardous Area Cables” within enclosure.

Non-Hazardous area cables shall be confined to area labelled “Non-Hazardous area cables” within enclosure.

Unused conductors shall be sheathed and tied back on incoming cable.

4. Pulse Inputs:- Shall be wired to monitor lead breakage and short circuit (refer to P

& F brochure for KFD2-SOT2-EX2) Cable entry to conduit shall be via cable gland and plain to screwed

conduit adapter. Shall use round conduit J-Box 2 way (normally)

5. Meter Cable:- Shall use meter manufacturer supplied meter cable complete with

pulse attachment. Shall use unjointed cable into J-Box via cable gland to IP 65. Cable shall be terminated across resistors as indicated.

6. J-Box:- Cables from J-Box to ISB enclosure shall be sealed at J-Box to

prevent gas migration along conduit using approved sealing mastic material. 1 x ½ Watt 10k OHM resistor 1 x ½ Watt 1k OHM resistor.

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Labelling for IS Barriers

1. Meter data cable shall have conductors labelled at the ISB relay terminations, e.g. meter ID No. 999 using wrap on labels.

2. Labelling shall be provided as indicated in drawing CTM-E05/2. 3. Enclosure cover shall be labelled “INTRINSIC BARRIER RELAY BOX” 4. Enclosure cover shall be labelled “FOR GAS METER ID XXX” 5. Enclosure cover shall have identified gas meter ID Nos. and channel allocation clearly

labelled.

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ANNEXURE 1

METER CONNECTION SCHEMATICS

(Next Page)

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11/12/2012 Page 16 of 41


ANNEXURE 2

ELECTRICAL METER WIRING DIAGRAM

(Next Page)

11/12/2012 Page 17 of 41


11/12/2012 Page 18 of 41


ANNEXURE 3

ELECTRICITY METER INSTALLATION CHECKLIST

Electrical

Meter:

Location:

ID #: Date:

Installing

Company:

Put an X in the check box when the checklist item has been addressed.

Facilities Engineer

Checklist Item Pass N/A Comment

Is there a need for a Digital Power Meter to be

installed and connected to EMACS for a new or

existing installation? If so, inform the meter

installation company before electrical contractor

progresses to determine position of CT’s.

Has the type of DPM (ION6200 or PQM II) been

established? This is dependent on if gas or water

meters are to be installed as well.

Has it been determined which company shall install

the communications? That is, the Meter Installer or the

EMACS Installer?

Has the UNSW Energy Manager been notified and

approval been given to proceed as per the UNSW

Electricity Meter Data form?

Have the hazards and potential risks of the installation

been identified?

Does a shutdown or outage need to be organised?

Meter Installation Company



been identified?

Has the type of DPM (ION6200 or PQM II) been

established? This is dependent on if gas or water

meters are to be installed as well.

Has the UNSW EMACS Electricity Meter Data form

been filled in for the various stages and approval given

to proceed?

11/12/2012 Page 19 of 41


Have the CT’s been sized according to the load and

required burden?

Has the best location for the CT’s, potential fuses,

links, terminals, DPM and communications equipment

been determined?

Do the CT’s and potentials need to be installed in the

Switchboard (SB) or Distribution Board (DB) or

Mechanical Control Centre (MCC)? If so, is this best

done by the SB or DB installers? If not, does a

shutdown need to be organised?

Can the meter be installed on the SB/DB/MCC or does

it require a new panel or can it be mounted in an

existing meter panel?

Has the method of connection to EMACS been

determined? Can it be connected to any existing

RS485 chain or is a new Modbus to Ethernet Bridge

required?

If a new Ethernet bridge is required, has a data port

been allocated by UNSW IT?

Have the labelling requirements been met?

Has the electricity meter and all necessary

documentation been handed over to the UNSW

Energy Manager? Failure to do so may hold back

payment.

EMACs Installer



been identified?

Has the method of connection to EMACS been

determined? Can it be connected to any existing

RS485 chain or is a new Modbus to Ethernet Bridge

required?

If a new Ethernet bridge is required, has a data port

been allocated by UNSW IT?

Has the meter been configured for the installation, eg

with CT ratios, Modbus address?

Has an ID number been returned by UNSW EMACS

representative?

Has the relevant information been passed onto

Provecta (EMACS software developer) to develop the

required screens?

11/12/2012 Page 20 of 41


Has the total installation been verified as per the Meter

Validation Sheet? i.e. the EMACS’ screen reflects

what the meter is showing and what has been read

from the portable power analyser?

Sign Off:

Facilities Engineer Name: Signature: Date:

Installer

Representative

Name: Signature: Date:

EMACs

Representative


11/12/2012 Page 21 of 41


ANNEXURE 4

WATER METER INSTALLATION CHECKLIST

Water

Meter:

Location:

ID #: Date:

Installing

Company:


Facilities Engineer


Has the water meter been sized for a single 20mm for

a main building or a single 32mm for an irrigation

meter? If not, has this been approved by the Manager

FM Engineering?

Is the water meter being installed for the main intake

of a building? If so, has connection to the EMAC

System been organised?

Does a sub-meter need to be installed as well if a

consuming plant or equipment uses more than 20% of

the total building Average Daily Demand? If so, has

connection to the EMAC System been organised?

Are accurate flow rates required? If so, then should an

analogue flow meter be installed?

Are water pressures required? If so, then should an

analogue pressure meter be installed?


approval been given to proceed?


been identified?




been identified?

Has the water meter been sized for a single 20mm for

a main building or a single 32mm for an irrigation

meter? If not has been approved by the Manager FM

11/12/2012 Page 22 of 41


Engineering?

Does the installation require a water meter based upon

being the main intake for a building or a sub-meter if

the consuming plant or equipment uses more than 20%

of the total building Average Daily Demand?

If so, then does the water meter have a pulse

attachment to connect to the UNSW EMAC metering

system?

Is the water meter a Davies Shepherd (Elster Metering

P/L) and is it acceptable to the UNSW?

Does the pulser provide an acceptable number of

pulses per volume based upon nominal expected

flows?

If a pulser is required, are there conduits in place

before the concrete is poured around the meter to

assist in cabling?

Is an analogue flow meter to be installed?

Is an analogue pressure meter to be installed?

Has the total installation been verified? i.e. check for

leaks, acceptable pressures?

Has the UNSW EMACS Water Metering form been

filled out completely?

Has the water meter and all necessary documentation

been handed over to the UNSW Energy Manager?

Failure to do so may hold back payment.

EMACs Installer



been identified?

Has conduits been put in place before the concrete is

poured around the meter to assist in cabling?

Has an analogue flow meter been installed?

Has an analogue pressure meter been installed?

What is the best method of connection to the UNSW

EMACS? Via a PQM Electrical Meter or a PLC?

Is a Modbus to Ethernet Bridge required or can the

communications be connected to an existing Modbus

chain?



11/12/2012 Page 23 of 41


required screens?

Has the total installation been verified with Provecta?

i.e. pulser signal is reaching EMACS and is accurate?

Sign Off:


Installer

Representative


EMACs

Representative


11/12/2012 Page 24 of 41


ANNEXURE 5

GAS METER INSTALLATION CHECKLIST

Gas Meter:

Location:

ID #:

Date:

Installing

Company:


Facilities Engineer


Is the gas meter being installed for the main intake of

a building? If so, has connection to the EMAC System

been organised?

Does a sub-meter need to be installed as well if a

consuming plant or equipment uses more than 20% of

the total building Average Daily Demand? If so, has

connection to the EMAC System been organised?

Has the installation been recognised or classified as a

hazardous area following the Hazardous Area Report

flowchart and check sheet?

Can the gas meter be installed outside in a suitable

location, if not in a well ventilated location to make

the installation Non-Hazardous?

What are the identified hazards and potential risks of

the installation? Is there external equipment that could

introduce a hazard or potential risk to the installation?

Are accurate flow rates required? If so, then should an

analogue flow meter be installed?

Are gas pressures required? If so, then should an

analogue pressure meter be installed?

Does automatic temperature and pressure correction

equipment on this gas meter justify the cost involved?

If not, then inform the Energy Manager for approval.


approval been given to proceed?




been identified, including the classification of the

11/12/2012 Page 25 of 41


installation being in a Hazardous Area?

Does the installation require a gas meter based upon

being the main intake for a building or a sub-meter if

the consuming plant or equipment uses more than 20%

of the total building Average Daily Demand?

If so, then does the gas meter have a pulse attachment

to connect to the UNSW EMAC metering system?

Is the type and make of pulse attachment acceptable to

the UNSW?

Is the gas meter of a diaphragm type, sized correctly

and is it acceptable to the UNSW?

Can the gas meter be installed outside in a safe

location, if not then in a well ventilated location? If

the gas meter is installed outside, is it housed in a

weatherproof enclosure?

Has the assembly been provided with upstream filter

& regulator and downstream regulator suited to the

connected equipment?

Does the pulse attachment provide an acceptable

number of pulses per volume based upon nominal

expected flows?

Is an analogue flow meter to be installed?

Is an analogue pressure meter to be installed?

Has the gas meter been fitted with automatic

temperature and pressure correction equipment?

Has the total installation been verified? i.e. check for

leaks, acceptable pressures?

Has a pressure measurement at the meter been taken to

provide information for EMACS calculations?

Has the UNSW EMACS Gas Metering form been

filled out completely?

Has the gas meter and all necessary documentation

been handed over to the UNSW Energy Manager?

Failure to do so may hold back payment.

EMACS Installer



been identified, including the classification of the

installation being in a Hazardous Area?

Is an IS Barrier required, dependent upon the gas

meter being classified as being in a Hazardous Area?

11/12/2012 Page 26 of 41


Has an analogue flow meter been installed?

Has an analogue pressure meter been installed?

What is the best method of connection to the UNSW

EMACS? Via a PQM Electrical Meter or a PLC?

Is a Modbus to Ethernet Bridge required or can the

communications be connected to an existing Modbus

chain?



required screens?

Has the total installation been verified with Provecta,

i.e. pulser signal is reaching EMACS and is accurate?

Sign Off:


Installer

Representative


EMACs

Representative


11/12/2012 Page 27 of 41


ANNEXURE 6

TYPICAL INTRINSIC SAFE BARRIER RELAY BOX ARRANGEMENT

(Next Page)

11/12/2012 Page 28 of 41


11/12/2012 Page 29 of 41


ANNEXURE 7

HAZARDOUS AREA REPORT

Table of Contents 1 Introduction 1.1 Objectives 1.2 References

2 Hazardous Area Classification 2.1 Responsibility 2.2 Hazardous Area 2.3 Source of Ignition 2.4 Probability of a Gas Hazard. 2.5 Area Classification 2.6 Methods of Classification. 2.7 Method of Protection.

3 The Verification Dossier 4 Inspection, Testing & Maintenance 4.1 Types of Inspection. 4.1.1 Initial Inspection 4.1.2 Periodic Inspection 4.1.3 Sample Inspection

4.2 Grades of Inspection. 4.2.1 Visual Inspection 4.2.2 Close Inspection 4.2.3 Detailed Inspection

5 Attachments 5.1 Determining a Hazardous Area Flow Chart 5.2 Flowmeter Location Check Sheet 5.3 Example of Area Classification for Gas Flowmeter 5.4 Example, Flammable Material List 5.5 Example, Source of Release List 5.6 AS/NZS60079.10:2004 Example of Sources of Release

11/12/2012 Page 30 of 41


1 Introduction

1.1 Objectives This report is designed to assist with determining the Hazardous Area Classification for the Natural

Gas Flow Meters located on the University of NSW Campus. It will also provide the methodology for

determining the grade of release and the requirements of a Hazardous Area Dossier.

1.2 References The following documents have and should be referenced for more information:

• AS/NZS 60079.10:2004

• AS/NZS 2430.3.1:2004

• AS/NZS 2430.3.4:2004

• AS/NZS 3000:2000

• AS/NZS 2381.1:1999

• AS 2380.7

• AS 2381.7

• AS 2380.1

• AS/NZS 60079.11

• AS/NZS 61241.1.2

• HB13-2000

2 Hazardous Area Classification

2.1 Responsibility The owner/occupier of the premises is usually responsible for the recognition and classification of

hazardous areas.

2.2 Hazardous Area A hazardous area is defined as an area in which an explosive atmosphere is present, or may be expected

to be present, in quantities such as to require special precautions for the construction, installation, and

use of potential ignition sources.

2.3 Source of Ignition An ignition source is a source of energy sufficient to ignite an explosive atmosphere. Common sources

of ignition are flames, welding and cutting operations, electrical arcing and sparking, and hot surfaces.

The ignition source must possess sufficient energy, temperature or a combination of energy and time in

order to ignite an explosive atmosphere.

2.4 Probability of a Gas Hazard The probability of a gas hazard actually occurring is dependent on their being a source of flammable

material. Sources of flammable material are called sources of release. These are broken down into three

basic grades by AS/NZS60079.10:2004, continuous, primary and secondary grades of release.

2.5 Area Classification Area classification should be carried out by those who are competent and have full knowledge of the

processes, apparatus concerned and of safety and personnel. The agreement reached on the

classification should be formally recorded and copies kept in the verification dossier. This dossier

needs to include an outline of the methods used to determine the area classification and reasoned

argument for justification of any decision that may prove controversial.

11/12/2012 Page 31 of 41


It is not possible to carry out a detailed appraisal without frequent reference to relevant standards.

AS/NZS60079.10:2004 Classification of hazardous areas should be used as a reference when

determining hazardous area classification.

Once it has been decided that an area is hazardous the next step is to classify the area. Areas which are

hazardous due to flammable gases are designated Zone 0, 1 and 2.

Other areas to be determined during the area classification are the gas group, gas type and the

maximum surface temperature (temperature class).

2.6 Methods of Classification Areas can be classified into Zone 0, 1 and 2 by either category of occupancy or by assessment. The

category of occupancy is well defined and the relevant authorities have agreed to their classification

and delineation. These areas are dealt with in AS/NZS 2430.3: Parts 3.1 to 3.9.

AS/NZS 2430.3.4:2004 is the part to use for examples of area classification for flammable gases.

2.7 Method of Protection Once it has been decided that an area is hazardous and it has been classified, suitable electrical

equipment can be chosen. There are many explosion-protection techniques, not all techniques are

suitable for use in all Zones. Intrinsically Safety (Exia) for example is a suitable explosion-protection

technique for Zone 0, 1 and 2 applications where Flameproof (Exd) is suitable for Zone 1 and 2 only.

The selected method of protection will depend on the area zoning, gas group, gas type and the

temperature class. Initial costs and costs to maintain the equipment must also factored into this

selection criteria.

3 The Verification Dossier

The verification dossier is defined in AS/NZS 2381.1:

The verification dossier is a living dossier it is used to house maintenance, inspections, repairs, test

results, modifications and changes to area classification. The dossier must be kept up to date.

The following items would be expected to be found in the dossier,

• Area Classification Documents

• Instructions for erection and connection

• Copies of equipment approval certificates

• Copies of equipment data sheets

• Maintenance schedules

• Inspection documentation

• Test documentation

• Maintenance reports, defects found and corrective actions.

• Reasoning for explosion-protection techniques

• Explosion-protection techniques calculations

4 Inspection, Testing & Maintenance

4.1 Types of Inspection There are three types of inspections, Initial, Periodic & Sample.

The results of these inspections shall be recorded in section 5.

11/12/2012 Page 32 of 41


4.1.1 Initial Inspection

All equipment, systems & installations shall be subject to an Initial Inspection before commissioning.

The Initial Inspection is a detailed inspection. The results of this inspection will be recorded in Sec.5.

4.1.2 Periodic Inspection

All equipment, systems & installations shall be subject to Periodic Inspections. These inspections are

either Close or Visual. The interval between inspections shall not exceed 4 years.

The results of this inspection will be recorded in section 5.

4.1.3 Sample Inspection

All equipment, systems & installations shall be subject to Sample Inspections; these inspections are

either Detailed, Close or Visual. These inspections should be used to monitor the effects of

environmental conditions, vibration, inherent design weakness & other faults.

The results of this inspection will be recorded in section 5.

4.2 Grades of Inspection There are three grades of inspections, Visual, Close & Detailed.

4.2.1 Visual Inspection

A Visual Inspection is an inspection that identifies, (without the use of access equipment or tools)

defects such as missing bolts, mechanical damage, etc that are apparent to the eye. A Visual Inspection

usually does not require the equipment to be opened or isolated.

4.2.2 Close Inspection

A Close Inspection is an inspection that encompasses those aspects of a Visual Inspection & in addition

identifies defects such as loose bolts, etc. This will only be apparent by using access equipment or

tools.

A Close Inspection usually does not require the equipment to be opened or isolated.

4.2.3 Detailed Inspection

A Detailed Inspection is an inspection that encompasses those aspects of a Close Inspection & in

addition identifies defects such as loose terminations, etc. This requires enclosures to be opened up &

equipment to be isolated.

5 Attachments

5.1 Determining a Hazardous Area Flowchart 5.2 Flow Meter Location Check Sheet 5.3 Example of Area Classification for Gas Flow Meter 5.4 Example, Flammable Material List 5.5 Example, Source of Release List 5.6 AS/NZS60079.10:2004 Example of Sources of Release

11/12/2012 Page 33 of 41


ATTACHMENT 7.1 DETERMINING A HAZARDOUS AREA FLOWCHART

11/12/2012 Page 34 of 41


ATTACHMENT 7.2 Natural Gas Flow Meter Area Classification Sheet

Natural Gas Flow Meter No.

Flow Meter Location

YES NO

1 Is the flowmeter installed outside

2 Is there plenty of natural ventilation

3 Is the gas pressure under 10kPa

If YES is checked for all of items 1, 2 & 3, the area can be classified as Non-hazardous

If NO is checked for any of items 1, 2 & 3, the area could be classified as hazardous & will need to be assessed

If NO is checked for only one of the items 1, 2 & 3, the area can still be classified as non-hazardous with the following justification…

Justification:

Flow meter installation checked by Print Name

Signature

Date

11/12/2012 Page 35 of 41


ATTACHMENT 7.3 EXAMPLE OF AREA CLASSIFICATION FOR GAS FLOW METER

11/12/2012 Page 36 of 41


ATTACHMENT 7.4 EXAMPLE FLAMMABLE MATERIAL LIST

11/12/2012 Page 37 of 41


ATTACHMENT 7.5 EXAMPLE SOURCE OF RELEASE LIST

11/12/2012 Page 38 of 41


ATTACHMENT 7.6 S/NZS60079.10:2004 EXAMPLE OF SOURCES OF RELEASE

Annexe 8.1 GAS Meter Form Page 39 of 41


E L E C T R I C I T Y Meter Data Form

Office Use Only Meter ID

Please return completed form to UNSW Energy Manager – Mathews Building Lv3

SECTION A. Installation of New Meter in New Location

Manufacturer Model

Building Name Grid Ref. Room

Floor Location Is meter external to building? Y/N

Meter Location Description

(Please be specific)

Load Description

What’s connected to the meter? (details)

SECTION B. Replacement of Existing Meter (in same location)

Existing Meter ID No. Serial No. Present Reading

New Meter Manufacturer Model

SECTION C. Change of Load / Disconnection ID No. Effective Date / / Load Change (Y/N) New CT Ratio Present Meter Reading

New Load Description


Disconnection (Y/N) Serial No. Final Meter Reading Reason For Disconnection

SECTION D. Installer Details

Name of Installer Contact No. Date / /

Name of Reporter Contact No. Date / /

Office Use Approved? Y/N Date / /

Special Condition(s)

Signature

TITLE: UNSW ENERGY MANAGER

EMS Recorder Contact No. Date / /

SECTION E. Completion

Energy Management : Has A Copy Of This Form Been Returned To Installer (Y/N)

Installer : When Meter Has Been Installed - Email [email protected] (Y/N)

And Provide The Following Information:

Serial No. CT Ratio Initial Reading

mailto:[email protected]

Annexe 8.3 Water Meter Form Page 40 of 41


GAS Meter Data Form




Manufacturer Model

System Pressure kpa Quantity per Pulse m3 Meter Bore Size mm





Load Description




New Meter Manufacturer Model

System Pressure kpa Quantity per Pulse m3 Meter Bore Size mm

SECTION C. Change of Load / Disconnection ID No. Effective Date / / Load Change (Y/N) New Pressure kpa New Pulse Quantity m

3 Present Reading



Disconnection (Y/N) Serial No. Final Meter Reading

Reason For Disconnection






Signature





Installer : When Meter Has Been Installed - Email [email protected] (Y/N)


Serial No. Present Reading

Annexe 8.3 Water Meter Form Page 41 of 41


WATER Meter Data Form




Manufacturer Water Quality (potable or bore)

Model Meter Bore Size mm Quantity per Pulse Litres





Load Description




New Meter Manufacturer Water Quality (potable or bore)

Model Meter Bore Size mm Quantity per Pulse Litres

SECTION C. Change of Load / Disconnection ID No. Effective Date / / Load Change (Y/N) New Quantity per Pulse Litres Present Meter Reading



Disconnection (Y/N) Serial No. Final Meter Reading

Reason For Disconnection






Signature





Installer : When Meter Has Been Installed Email [email protected] (Y/N)


Serial No. Initial Reading