LIST OF ELECTRICAL STANDARD SPECIFICATIONS 01 Codes for electrical equipment 02 Preparation of electrical documents 03 Incoming substations 04 Departmental substations 05 Medium voltage switchboards 06 Power transformers 07 Power control centres, motor control centres 08 Large motors 09 Small motors 10 Starters 11 Variable speed drives 12 Erection, cabling, earthing connections, lightning protection 13 Production and distribution of auxiliary voltages 14 Electrical cabinets and marshalling cabinets 15 Instrumentation 16 Process Control System : equipment and configuration 17 Process Control System: application software and integration 18 Lighting and power outlets 19 Electrical devices for mechanical equipment 20 Earthing grid 21 Process Control System : basic functional objects 22 Visible Cut-off Switches 23 Incoming transformers Key codes: Low voltage, Power, Motor Control Centre, MCC, Cabinet F E D C B A 21/10/05 General revision I. MOCANU M. MAHAUX 0 07/10/02 Document edition I. MOCANU M. MAHAUX Approved Rev Date Scope of revision Issued Approved CTI CTEC LAFARGE CENTRE TECHNIQUE INTER-UNITES LAFARGE CENTRE TECHNIQUE EUROPE CENTRALE L’Isle d’Abeau – Parc de Chesnes – B.P. 70 Gumpendorfer Strasse 19-21, F-38291 ST QUENTIN-FALLAVIER Cedex A-1060 WIEN, Postfach 264 Phone : + 33 474 82 16 16 / Fax + 33 474 94 30 07 Phone : + 43 1 811 42 0 / + 43 1 811 42 44 09 ASIA TECHNICAL CENTRE Level 3,Wisma Lafarge N°2 Jalan Kilang 46050 PETALING JAYA – SELANGOR DARUL EHSAN MY-MALAYSIA Phone : + 603 77874800 / Fax : + 603 77874890 Reproduction & usage strictly forbidden without Lafarge ELECTRICAL STANDARD th explicite agreement (Law March 11 , 1957) SPECIFICATION POWER CONTROL CENTRES, Document Page Rev. MOTOR CONTROL CENTRES STD002.U07 1/31 A CONTENT 1. GENERAL REQUIREMENTS 4 1.1. APPLICABILITY 4 1.2. APPLICABLE STANDARDS 4 1.3. LOCAL CONDITIONS 4 1.4. GLOSSARY 4 1.5. SIGNS USED 4 1.6. ENCLOSURE AND DEGREE OF PROTECTION 5 1.7. RATED VOLTAGES 5 1.7.1. Main voltage......................................................................................................................... 5 1.7.2. Auxiliary voltages ................................................................................................................. 5 1.8. RATED INSULATING VOLTAGE 5 1.9. RATED CURRENTS 5 1.10. SHORT CIRCUIT WITHSTAND STRENGTH 6 2. SWITCHBOARD CONSTRUCTION 6 2.1. COMMON REQUIREMENTS 6 2.1.1. General arrangement .......................................................................................................... 6 2.1.2. Switchboard structure .......................................................................................................... 6 2.1.3. Incoming circuit(s)................................................................................................................ 7 2.1.4. Busbars ................................................................................................................................ 7 2.1.5. Control and measuring circuits ............................................................................................ 7 2.1.6. Remote Input/Output modules ............................................................................................ 8 2.1.7. Wiring ................................................................................................................................... 8 2.1.8. Labels................................................................................................................................... 9 2.2. DRAW-OUT / FIXED TYPES 9 2.2.1. Draw-out type ...................................................................................................................... 9 2.2.2. Fixed type .......................................................................................................................... 10 3. POWER SWITCHGEAR 11 3.1. INCOMERS AND BUS-TIE BREAKERS 11 3.2. OUTGOING CIRCUITS 11 4. CONTROL SWITCHGEAR AND MEASURING DEVICES 12 4.1. CONTROL CIRCUITS 12 4.2. PROTECTIONS 13 4.3. MEASURING DEVICES 14 5. PCC/MCC SUPPLYING VSDS 14 6. POWER FACTOR CORRECTION UNITS 15 POWER CONTROL CENTRES, Document Page Rev. MOTOR CONTROL CENTRES STD.002.U07 2/31 A 7. DOCUMENTS 16 7.1. DOCUMENTS TO BE SUPPLIED BY THE OWNER 16 7.2. DOCUMENTS TO BE PREPARED BY THE SUPPLIER 16 7.3. DOCUMENTS TO BE SUBMITTED WITH THE OFFER 17 8. FACTORY TESTS 17 9. GUARANTEE 18 10. DATA SHEETS 18 11. SWITCHGEAR SELECTION TABLES 21 11.1. SWITCHGEAR SELECTION FOR 400 V MOTORS USING LINE STARTERS 21 11.2. SWITCHGEAR SELECTION FOR 500 V MOTORS USING LINE STARTERS 22 12. DIAGRAMS 23 POWER CONTROL CENTRES, Document Page Rev. MOTOR CONTROL CENTRES STD.002.U07 3/31 A 1. GENERAL REQUIREMENTS 1.1. APPLICABILITY This specification is applicable to Power Control Centres (Low Voltage Distribution Boards) as well as to Motor Control Centres operating in 3-phase AC under a voltage not exceeding 1000 V. 1.2. APPLICABLE STANDARDS The panels shall comply with the requirements of IEC and ISO standards. In particular, they shall be prefabricated, type-tested assemblies according to IEC 60439-1 standard. 1.3. LOCAL CONDITIONS Local conditions are given in the Site Specification. Equipment subject to this specification will be installed in electrical rooms protected from the dust. The ambient air temperature will not exceed + 40°C nor be less than - 5°C and its average over a period of 24 h will not exceed + 35°C. If required by climatic conditions, anti-condensation heaters shall be installed. 1.4. GLOSSARY ACC Auxiliary Control Centre MCB Miniature circuit breaker MCC Motor Control Centre PCC Power Control Centre PCS Process Control System UPS Uninterruptible Power Supply VCS Visible Cut-Off Switch VSD Variable Speed Drive 1.5. SIGNS USED A sign in the margin will mark up in the text of this specification each clause to be mandatorily specified by the Site Specification. POWER CONTROL CENTRES, Document Page Rev. MOTOR CONTROL CENTRES STD.002.U07 4/31 A 1.6. ENCLOSURE AND DEGREE OF PROTECTION Switchboards enclosures shall ensure in normal service (doors closed) a protection degree IP31 according to IEC 60529, IP20 with door open or drawer in test or drawn-out position. 1.7. RATED VOLTAGES 1.7.1. Main voltage This voltage is mentioned in the Site Specification, as well as the condition of the neutral point. The default value for a new plant with a frequency of 50 Hz is 400 V, three-phase. Unless otherwise mentioned, the neutral will be solidly earthed and not distributed. 1.7.2. Auxiliary voltages These voltages are mentioned in the Site Specification. The default values for a new plant are : 230 V AC Normal for contactor coils and anti-condensation heaters. 230 V AC UPS for electronic modules and contactor coils when protection against feeder voltage dips is required. 24 V DC for auxiliary relays and signalling lamps. All these auxiliary voltages will be supplied by the ACC (out of this supply), as developed in Specification STD.002.U13. A 1.8. RATED INSULATING VOLTAGE The insulation voltage for the busbars and power switchgear as well as for any circuit of the switchboard shall not be less than: Busbars: 1 000 V Power switchgear: 690 V Power circuits: 750V Control switchgear and circuits: 500 V 1.9. RATED CURRENTS The rating of the incoming circuit(s) shall be in accordance with the feeding transformer, and at least equal to the total load of the users supplied, if the power of the feeding transformer is not known. The rating of the main busbar(s) shall not be less than this one of the incoming circuit(s). Same rating shall be considered for the full length of each main busbar (no reduced cross section at ends). POWER CONTROL CENTRES, Document Page Rev. MOTOR CONTROL CENTRES STD.002.U07 5/31 A Unless otherwise specified, every switchboard shall be designed for a continuous service. 1.10. SHORT CIRCUIT WITHSTAND STRENGTH The rated short-time withstand current of the switchboard shall at least be equal to the short- circuit current mentioned in the particular specification and shall in no case be less than 50 kA rms during 1 s. This shall also apply to the incoming circuit breaker, to bus-tie breakers and to outgoing circuit breakers (please refer to section 3). 2. SWITCHBOARD CONSTRUCTION 2.1. COMMON REQUIREMENTS A 2.1.1. General arrangement The switchboard shall be defined with access to switchgear and to cables from the front only. The switchboard shall be designed so that its sections (columns) can be installed either in one line or back to back (busbars shall be independent and segregated). The main busbar shall be positioned on top or on the back of the switchboard and cables shall enter from the bottom. If an incoming bus duct is used, this could enter from the top. The switchboard shall be designed to be installed directly above the cable channel or on technical floor without the addition of any part not supplied by the Supplier. The switchboard shall be designed for easy extension at least at one end. All the switchboard components: busbars, outgoing feeders and its dimensions shall be standardized as much as possible. A minimum of 10% empty spare space shall be provided. 2.1.2. Switchboard structure The switchboard shall be of modular and prefabricated type, assembled and equipped in the factory. No section shall be higher than 2200 mm and access to each piece of equipment and device shall be easy, especially for resetting thermal overload protection relays or for manoeuvring MCBs protecting auxiliary circuits. POWER CONTROL CENTRES, Document Page Rev. MOTOR CONTROL CENTRES STD.002.U07 6/31 A Anticorrosion protection of the metal structure (internal and external sides) shall be ensured as follows: Continuous hot dip galvanised sheet metal shall be used for non visible internal metal parts. Visible metal parts shall be prepared by phosphatisation-cleaning treatment and painted with either epoxy-polyester powder (minimum thickness 50 m) or acrylo-urethane lacquer (minimum thickness 20 m). The finish shall be semi-gloss; the colour will be the Manufacturer’s standard shade unless otherwise specified. Ample passage shall be designed for the cables arriving from below, and supporting clamps shall be available for fixing power and control cables. Cable channel width shall not be less than 300 mm. Dust ingress and fire transmission will be stopped by closing these cable passages, after cables installation, with fire resisting materials (operation performed by the cabling contractor). Each switchboard section shall be equipped with a vertical copper earth collector connected A to an horizontal copper earth collecting bar. This shall terminate to an earthing tail, accessible when the board is alive and suitable for connecting a copper earthing cable. The cross section of this earth collector shall be such that it will withstand the switchboard’s short- circuit current during 1 s, with a minimum cross section of 200 mm². Switchboards shall be form 2 with doors open. At the minimum, Plexiglass (perspex) A screens will be provided in order to avoid contacts with live conductors (busbars and power connections). Each access door shall be locked by a single handle without key nor need of using any tool as these switchboards will be installed in locked electrical rooms. 2.1.3. Incoming circuit(s) The incoming section(s) shall be designed for connection to incoming feeder(s) either by busbar provided with flexible connection or by cables. A 2.1.4. Busbars Main busbars (horizontal) and vertical busbars shall be of electrolytic copper type Cu ETP according to ISO 1337 standard. Busbars which do not require maintenance shall be provided. Metal sheets near high current busbars (1 600 A or more) shall be of aluminium or of other non magnetic material. All bolted connections shall be checked by using a torque wrench. 2.1.5. Control and measuring circuits Every control equipment shall be accessible from the front of the switchboard. Every signalling switchgear and every indicator shall be visible from the front of the switchboard. POWER CONTROL CENTRES, Document Page Rev. MOTOR CONTROL CENTRES STD.002.U07 7/31 A 2.1.6. Remote Input/Output modules Unless otherwise mentioned in the Site Specification, digital remote Input/Output modules and their associated communication modules shall be installed by the Supplier on top of each switchboard section, in a compartment separate by a metal sheet from the portion devoted to switchgear’s installation. Unless otherwise provided in the Site Specification, these I/O modules are not a part of this supply. Every device of these modules shall be accessible directly from the front of the switchboard, without having to remove any part. Indication LEDs of I/O modules and of communication modules shall be perfectly visible to a person standing in front of the switchboard, with its doors closed. 2.1.7. Wiring The switchboard wiring shall be performed in accordance with the Lafarge standard schematic diagrams included in section 12 of this document. A Terminal strips shall allow easy maintenance access to each wire terminal. They shall be segregated between: Power circuits AC control circuits DC control circuits. Terminals: Power terminals : screw type up to 16 mm² core section, with a cable lug for larger cables ; Control terminals : shall be of insulation displacement type (needing no special tool for completing the connection) or of spring type. Connectors with plug and sockets (several stages if necessary) shall be provided for control terminals of plug-in modules. Auxiliary voltages distribution to the different circuits will preferably be by adequate prefabricated busbars. These busbars shall be adequately insulated to prevent any accidental contact. Control wires shall be flexible, 500 V PVC insulated with a minimum core section of 1 mm². A Each wire shall be labelled or marked up at each end with the number of the terminal it is connected to, according to manufacturer’s standard procedures. Wires shall be installed in trunkings of adequate sections. POWER CONTROL CENTRES, Document Page Rev. MOTOR CONTROL CENTRES STD.002.U07 8/31 A 2.1.8. Labels Following labels shall be provided and installed : Switchboard main label installed at the upper left front part of the switchboard and indicating the tag (Lafarge code) and the description of the switchboard. Switchboard indicating plate installed just under the main label and indicating : manufacturer, year, rated voltage, rated insulating voltage, incoming and main bus bar rated currents, short circuit withstand current. Section (column) number label installed on the upper middle front part of each section or of its door. Module (plug-in type) or drawer (draw-out type) tag label to be secured to the fixed part facing to corresponding module or drawer, indicating the tag (Lafarge code) and the description of the circuit. Labels shall be engraved in black - cored white dilophane and fixed by screws or rivets (glue not accepted). Letters’ height shall be at least : 15 mm for the switchboard main label 6 mm for the incoming, bus-tie and outgoing circuits labels 4 mm for the auxiliary circuits. 2.2. DRAW-OUT / FIXED TYPES The Owner will specify whether the switchboard shall be of draw-out or plug-in type. 2.2.1. Draw-out type The switchboard shall be form 3b (at least). Each outgoing circuit shall be at least Service Index 333: A Operation: control circuits can be tested with the power circuit off Maintenance: after switching it off, any outgoing circuit module can be removed and inserted without switching off the switchboard Evolution: new outgoing circuits can be installed without switching off the switchboard. Each drawer shall have 4 positions: Connected (power and control on) Test (power of, control on) Disconnected (power and control off) Removed. It shall be possible to lock out each drawer in « disconnected » position by up to 3 padlocks. POWER CONTROL CENTRES, Document Page Rev. MOTOR CONTROL CENTRES STD.002.U07 9/31 A Power circuits shall be automatically disconnected in « disconnected » positions, as well on upstream side than on downstream side. Control circuits shall be disconnected in « removed » position either automatically or manually by disconnecting a plug where pass all the control circuits through. Such disconnection/reconnection operation shall not need the use of any tool. A contact from the drawer shall inform the PCS (and the operator) that this circuit is unavailable when the drawer is in “disconnected” or “removed” position. A defeater (mechanical interlocking system) shall be installed on each fixed part and on each drawer to prevent from introducing a drawer of an inappropriate type or rating. Signalling lamps and instruments (current and active power indicators) shall be installed in front of drawers. 2.2.2. Fixed type The switchboard shall be of modular type form 2b (at least), except sections housing incomers and bus-tie breakers which shall be form 3b. Each outgoing circuit shall be mounted and wired on an individual metal sheet plate, also modular and standardized. It shall be possible to install or remove such modules fully A equipped without dismantling the adjacent modules or other cubicle parts or accessories. Each outgoing circuit shall be at least Service Index IS 322, which means : Operation : control circuits can be tested with the power circuit switched off. Maintenance : after switching it off any outgoing circuit module can be removed without switching off the switchboard. Evolution : new outgoing circuits can be installed, if spare spaces exist, without switching off the switchboard. This plate shall support power connectors to be plugged in the busbar. It shall also support a connector for connecting all the control circuits of the module. No connection with another outgoing circuit or with switchboard common circuits shall be performed without passing through these plugs and connectors. Each modular plate shall also support signalling lamps and instruments (current and active power indicators). Alternatively, these items can be installed and wired to the front door. If signalling lamps and instruments are mounted on the plates, each switchboard section supporting outgoing circuits shall be equipped with a safety glass door with a rubber seal. POWER CONTROL CENTRES, Document Page Rev. MOTOR CONTROL CENTRES STD.002.U07 10/31 A 3. POWER SWITCHGEAR 3.1. INCOMERS AND BUS-TIE BREAKERS The incomers and bus-tie breakers shall have their protection devices co-ordinated with the outgoing circuit breakers to guarantee a good selectivity. On feeders already protected on upstream side (for instance by a circuit breaker connected to the secondary winding of the feeding transformer) power switches (or circuit breakers without protection relays) shall be installed to avoid unnecessary selectivity steps. Each circuit breaker or power switch shall be of draw-out type. It shall be equipped with a system for locking out with 3 padlocks. Each circuit breaker or power switch shall also have a closing auxiliary contact (normally open) for initiating an alarm when in open position. Emergency busbar (when applicable) shall be supplied in normal condition from the main busbar; in case of power failure from the emergency generator. Changeover shall be by A 2 circuit breakers or contactors mechanically interlocked to avoid paralleling these 2 sources. If neutral is isolated, an insulation check meter shall be installed on incoming circuit, with an alarm contact open on low insulation resistance. An emergency shut-down push button (red mushroom to be turned for unlatching) shall be installed on the incoming section (column) of the switchboard and wired to switchboard’s terminals. 3.2. OUTGOING CIRCUITS Each outgoing circuit shall be protected by a circuit breaker from short circuits and instantaneous overcurrents; fuses are not accepted. This circuit breaker shall be capable to withstand the full short circuit current. Its protection system shall be co-ordinated with cables core section and cables length according to IEC rules (short-circuit condition, overload condition, voltage drop, installation conditions, protections against indirect contacts, ...). Its handle shall provide for locking it out with up to 3 padlocks. Each outgoing circuit to a motor shall be protected by a thermal overload protection. Such protection can be provided by a separate overload relay tripping the contactor coil. It can also be integrated in the above mentioned circuit breaker. If separate from the circuit breaker, it shall also be co-ordinated according to IEC rules (overload condition). For protecting motors driving large inertia equipment with long start-up time such as fans with a power of 11 kW or more, heavy duty starters or electronic soft starters shall be used. Each motor shall be operated by a contactor (or two contactors for two directions motors and two speeds motors). POWER CONTROL CENTRES, Document Page Rev. MOTOR CONTROL CENTRES STD.002.U07 11/31 A Each contactor shall be dimensioned for an AC-3 service according to IEC 60947-4 with following derating: the contactor rated current shall be at least equal to : 150% of user’s rated current for motors up to 55 kW 130% of user’s rated current for larger motors. Switchgear items of each outgoing circuit shall have a type 2 co-ordination according to IEC standard, resulting in the absence of contacts’ welding and of damage on protection system after any electrical failure. The Supplier shall also check the compliance of equipment supplied with starting conditions (magnetisation current, long starting time, …) Outgoing circuits shall be standardised in order to reduce quantities of spare parts to be kept in the warehouse. Protection functions (magnetic and thermal overload) and operating function can be grouped in a combined equipment provided that the operated motor power does not exceed 22 kW. Considering all the switchboards included in the Supply, following spare outgoing circuits shall be supplied (fully equipped) : 2 units for each rating of 1 direction motor feeder up to 15 kW 1 unit for each rating of: - 1 direction motor feeder above 15 kW ; - 2 directions motor feeder ; - circuit breaker outgoing feeder. The approval of the Owner shall be required on the choice of the switchboards where these spare circuits will be installed. 4. CONTROL SWITCHGEAR AND MEASURING DEVICES 4.1. CONTROL CIRCUITS On each incoming, bus-tie or outgoing circuit shall be installed two Miniature Circuit Breakers : 1 MCB for protecting AC control circuits ; 1 MCB for protecting DC control circuits. In case of a double busbar with a bus-tie, the three incoming/bus-tie circuit breakers/switches shall have their trip coils interlocked to prevent any paralleling of sources. A The KA relay that controls the contactor kW shall be of safety relay type (IEC). POWER CONTROL CENTRES, Document Page Rev. MOTOR CONTROL CENTRES STD.002.U07 12/31 A A no-volt relay shall be installed in the incomer compartment; this relay equipped with a timer A (0 to 1 sec) shall cut off the contactor’s auxiliary voltage 230 VAC (recommended setting 0.5 sec). The contact of this relay shall be connected in the series with the emergency shut-down contacts. In case of an emergency busbar an automatic switchover system shall be supplied to change the sources in case of power failure and when the power is back. Auxiliary contacts of the switchboard system shall be wired to switchboard’s terminals in order to inform the PCS. A Each outgoing circuit shall be equipped with signalling lamps indicating : Green: - running direction 1 / speed 1 - running direction 2 / speed 2 (if applicable) Yellow: Circuit available (drawer in operation position, power switch and/or circuit breaker closed, thermal overload protection in normal position, auxiliary voltages MCBs closed) Red: Trip (circuit breaker and thermal relay). These lamps shall use Light Emitting Diodes (bulbs with a filament are not accepted). Lamp colours are shown on Lafarge standard schematic diagrams (please refer to section 12). Unless otherwise mentioned in the Site Specification, each control circuit (and each alarm circuit) shall be connected to Remote Digital Input/Output modules to be installed on top of each switchboard section (column) in a closed compartment isolated by a metal sheet from the rest of the section. These modules will communicate with the PCS. Unless otherwise mentioned, the supply of these RI/O modules and their associated devices (power supply, connectors, ...) is not included in this scope of work. This in order to minimise site cabling and be able to perform a maximum of tests at the workshop. Alternatively, for incoming circuits, the metering units mentioned in section 4.2 can be used for the transmission of their control signals to the plant control system. When required by the Site Specification, the switchboard shall be intelligent. Each incoming and each outgoing circuit shall be controlled by a fieldbus connected to the PCS. It shall be possible to modify the parameters of these circuits through this fieldbus. Each outgoing circuit shall be wired up in accordance with the Lafarge standard schematic diagrams under section 12. Inter allia, terminals shall be supplied for connecting local START and STOP commands from the VCS supplied by others. 4.2. PROTECTIONS Following alarms shall be made available to the PCS : Incoming/bus-tie breaker is in off position (please refer to section 3.1); MCB protecting AC control circuits is in off position (please refer to section 4.1); POWER CONTROL CENTRES, Document Page Rev. MOTOR CONTROL CENTRES STD.002.U07 13/31 A MCB protecting DC control circuits is in off position (please refer to section 4.1); Insulation resistance too low if an insulation checkmeter is installed at the incoming feeder (please refer to section 3.1). The emergency shut-down push-button installed on incoming section (please refer to section 3.1) will trip the MV circuit breaker feeding the transformer supplying this switchboard (cabling to be performed by the cabling contractor). 4.3. MEASURING DEVICES Every current transformer shall have a secondary winding rated for 1 A, and shall withstand the maximum possible short circuit current. An electrical parameters’ metering unit shall be installed on each incoming circuit. This shall measure at least following parameters : 3U, 3V, 3I, P, Q, S, f and PF and display these parameters (according to operator selection). This unit shall also meter active and reactive energies and provide a pulse output for active energy. This metering unit shall also monitor the presence of the three phases and send an alarm through the fieldbus (see below) in the absence of one or several phases, or in case of failure of this device. It shall include communication with the PCS by a fieldbus PROFIBUS DP. On this fieldbus shall be made available all above measurements and alarms. Every outgoing circuit supplying a motor with a power of 30 kW or more or a material handling equipment (screw conveyor, bucket elevator, chain conveyor, belt conveyor, …) of any power shall be equipped with a current transducer converting the full motor current range in a 4-20 mA DC signal connected to the plant control system through outgoing terminals and to a current indicator installed on the drawer front/plate or adjacent to it. The current transducer and the current indicator shall be replaced by an active power A transducer and an active power indicator for bucket elevators and for cooler drag chains. 5. PCC/MCC SUPPLYING VSDS These LV boards shall be provided with two motorised incoming circuit breakers supplying two separate 3-phase busbars (please refer to the diagram indicated in section 12). Their simultaneously switching-on and switching-off shall be ensured by a dedicated control circuit. Each 3-phase incoming feeder shall be provided with following protections : A surge protection on each phase An insulation check meter The outgoing circuits supplying VSDs shall be equipped with fast fuses. The loads of each bus bar shall be balanced as far as possible. A single line diagram of the switchboard shall be submitted to the Owner’s approval. POWER CONTROL CENTRES, Document Page Rev. MOTOR CONTROL CENTRES STD.002.U07 14/31 A 6. POWER FACTOR CORRECTION UNITS Unless otherwise specified, a power factor correction unit shall be supplied with each set of PCC/MCC. The reactive power of this unit shall be calculated so to increase the power factor of the switchboard from natural value (typically 0.7) up to 0.92 unless more stringent A requirements from the Site Specification. Following table indicates the minimum rated power required for power factor correction units according to the transformer rated power supplying this set of PCC / MCC: Feeding transformer rated Power factor correction power unit rated power required (kVA) (kVAR) 630 275 1000 425 1250 520 1600 675 2000 850 2500 1050 This power factor correction unit shall be of automatic type, connecting or disconnecting the capacitor banks by steps according to power factor fluctuations. Steps shall not exceed 50 kVAR each. All the capacitor banks shall be identical. It shall be housed in a separate cabinet to be installed either at the end of the PCC or MCC or behind their incoming section. This cabinet’s look shall match as much as possible with A the PCC or MCC. It shall be connected to corresponding PCC or MCC by an outgoing circuit breaker of appropriate rating. It shall be designed in order to be remotely turned on and off. The protection against harmonic currents will be considered taking into account the ratio k between the power of harmonics generated and the power of the transformer feeding the PCC/MCC : k < = 15% : no harmonic protection required k > 15% and < = 25% : reinforced type is required k > 25% and < = 50% : anti-harmonic inductances are required k > 50% : anti-harmonic filters are required The type of protection against harmonic currents shall be submitted to the Owner’s approval. POWER CONTROL CENTRES, Document Page Rev. MOTOR CONTROL CENTRES STD.002.U07 15/31 A The protection fuses shall be provided with a trigger , with trip local signalisation and one A NC contact for remote alarm. Each unit shall be equipped with discharge resistors for operator’s safety. Note: For new department electrical distribution, at least, reinforced type is required. 7. DOCUMENTS 7.1. DOCUMENTS TO BE SUPPLIED BY THE OWNER Site Specification which details site conditions, voltages, … Particular Specification : this document, complemented with a single line diagram if required, shall specify, when not mentioned in the Site Specification : draw-out or plug-in type sections arrangement back-to-back or in one row incoming (stand-by) rated currents short circuit current to be considered for each board emergency busbar rated current (if applicable) power factor correction unit rated power required or power factor to be achieved with all the users in operation. Consumers’ List specifying for each user : rated power rated current rated voltage type of circuit (with/without contactor, one way/two ways, normal/heavy start) accessories (current/active power transducer and indicator) power cable core section (the Supplier to mention when it needs this document). 7.2. DOCUMENTS TO BE PREPARED BY THE SUPPLIER Following documents shall be prepared in English (unless otherwise stated in the Site Specification) in accordance with the requirements of specification STD.002.U02. Single Line Diagram giving references of upstream equipment : feeders’ tag numbers, upstream single line diagrams, ... Selectivity Study demonstrating that protections are effective and co-ordinated. Lay-Out of each switchboard with dimensions and position of each circuit. POWER CONTROL CENTRES, Document Page Rev. MOTOR CONTROL CENTRES STD.002.U07 16/31 A Lay-Out of each module (Typical) Civil Works Guide Drawing for each switchboard. Typical Detailed Schematic Diagrams for each circuit type (including auxiliary circuits). These diagrams shall also mention the number of every terminal. Interlocking Diagrams if applicable. Equipment list of Switchgear installed with technical details. Application software of each programmable equipment. Interface tables of exchange (addresses clearly indicated) of each programmable equipment. Manufacturing Time Schedule. Installation and Maintenance leaflets. Recommended Spare Parts Lists : for commissioning for 2 years operation. 7.3. DOCUMENTS TO BE SUBMITTED WITH THE OFFER A Following documents shall be submitted in English with bid: Detailed specification of the proposed equipment Technical characteristics of each switchboard Front face and dimensions of each switchboard Type tests certificates according IEC 60439-1 for: Icc – 50 kA 1s Ingress protection certificate. 8. FACTORY TESTS The Supplier shall notify the Owner not less than 14 days prior to the testing period, in order that the Owner may, should he think it necessary, delegate a representative to witness these tests. Following tests shall be performed on each switchboard, according to IEC 60439-1 standard, A completely assembled except main busbars’ connections between sections which are to be separately packed for despatch and a detailed test procedure be submitted to the Owner prior starting the tests. Measuring insulation resistances (power and control circuits) Dielectric tests (power and control circuits) POWER CONTROL CENTRES, Document Page Rev. MOTOR CONTROL CENTRES STD.002.U07 17/31 A Operation tests Check of interlockings and safety devices Check of drawers interchangeability (if applicable) Check of dimensions and accessories. The Supplier shall also supply copies of type test reports proving the short circuit withstand of the switchboard. All these factory tests/type tests will be performed at the Supplier's expenses. A detailed test report shall be prepared by the Supplier and handed over to the Owner’s representative or mailed to the Owner if it has not witnessed the tests. 9. GUARANTEE Minimum required guarantee is 24 months after commissioning, with a maximum of 30 months after the switchboards are ready for factory tests. 10. DATA SHEETS POWER CONTROL CENTRES, Document Page Rev. MOTOR CONTROL CENTRES STD.002.U07 18/31 A CUSTOMER: SUPPLIER : PROJECT: DATA SHEET PROJECT No: POWER CONTROL CENTRE, MOTOR OFFER: CONTROL CENTRE EQUIPMENT: DATE : Type 1 Draw-out/Plug-in 2 Protection degree IP 3 Segregation Form 4 Service index IS Manufacturer 5 Cabinets 6 Switchgear Service conditions 7 Rated voltage V 8 Insulation voltage V 9 Short-time withstand current kA Incoming circuit 10 Rated current of main circuit breaker A 11 Short circuit current of main circuit breaker kA 12 Feeder by busbar/cables 13 Measurement device 14 Insulation checkmeter (if applicable) Busbars 15 Main busbars (horizontal) rated current A 16 Material / cross section 17 Secondary busbars (vertical) rated current A 18 Material / cross section 19 Maintenance required Control 20 Remote I/O modules / intelligent switchboard Accessories 21 Anti-condensation heaters required Yes/No 22 Others Yes/No Dimensions 23 Switchboard height mm 24 Switchboard depth mm 25 Switchboard length mm 26 Cable channel width mm Painting 27 Preparation 28 Finish 29 Deviations from this specification POWER CONTROL CENTRES, Document Page Rev. MOTOR CONTROL CENTRES STD.002.U07 19/31 A CUSTOMER: SUPPLIER : PROJECT: DATA SHEET PROJECT No: LV POWER FACTOR CORRECTION UNIT OFFER: EQUIPMENT: DATE : 1 Type 2 Manufacturer 3 Rated voltage V 4 5 Insulation voltage Total capacity V kVAr 6 Capacity of each step kVAr Power factor regulation V 7 Regulation load relays in each unit Yes/No 8 Remote turn on and off Yes/No Protection against harmonic currents 9 Reinforced protection Yes/No 10 Anti-harmonic inductance Yes/No 11 Anti-harmonic filters Yes/No Dimensions 12 Cabinet height mm 13 Cabinet depth mm 14 Cabinet length mm Painting 15 Preparation 16 Finish 17 Deviations from this specification Notes: 1. Values to be mentioned in boxes marked with sign are to be given by the Owner or by the Formatted: Indent: Left: 0.3", Hanging: 0.2", Numbered + Level: 1 + Numbering Style: main Contractor. 1, 2, 3, … + Start at: 1 + Alignment: Left + 2. The Supplier is requested to fill in a data sheet for each type of equipment proposed and to Aligned at: 0.54" + Tab after: 0.79" + Indent at: 0.79", Tab stops: Not at 0.79" return it with its proposal. POWER CONTROL CENTRES, Document Page Rev. MOTOR CONTROL CENTRES STD.002.U07 20/31 A 11. SWITCHGEAR SELECTION TABLES 11.1. SWITCHGEAR SELECTION FOR 400 V MOTORS USING LINE STARTERS Current P (kW) (A) Contactor Thermal C-breaker * CT Ratio 0.25 0.8 25 0.63 to 1 0.37 1.1 25 1.00 to 1.6 0.55 1.6 25 1.00 to 1.6 0.75 2 25 1.60 to 2.5 1.1 2.5 25 1.60 to 2.5 1.5 3.3 25 2.50 to 4.0 2.2 4.6 25 4.00 to 6.0 3 6.0 25 4.00 to 6.0 4 8.4 25 7.00 to 10 5.5 11 25 10.0 to 13 7.5 15 25 13.0 to 18 11 20 40 18.0 to 25 15 28 40 23.0 to 32 18.5 34 63 30.0 to 40 22 40 63 38.0 to 50 25 47 80 0.63 to 1 50/1 30 55 80 " 60/1 37 66 115 " 100/1 55 100 185 " 125/1 75 128 185 " 150/1 90 156 265 " 200/1 110 205 265 " 250/1 132 224 400 " 250/1 160 280 400 " 300/1 200 349 400 “ 400/1 250 434 630 “ 630/1 Up to 63 A, circuit breakers are equipped with thermal overload and magnetic protection circuits rated for standard motors. * to be filled by MCC Supplier for type 2 co-ordination (please refer to section 7.2). The number of circuit breaker sizes will be limited to reduce spare part stock. POWER CONTROL CENTRES, Document Page Rev. MOTOR CONTROL CENTRES STD.002.U07 21/31 A 11.2. SWITCHGEAR SELECTION FOR 500 V MOTORS USING LINE STARTERS Current P (kW) (A) contactor Thermal C-breaker * CT ratio 0,25 0,8 25 0,63 to 1 0,37 1,1 25 1,00 to 1,6 0,55 1,6 25 1,00 to 1,6 0,75 2 25 1,60 to 2,5 1,1 2,5 25 1,60 to 2,5 1,5 3,3 25 2,50 to 4 2,2 4,6 25 4,00 to 6 3 6 25 4,00 to 6 4 8,4 25 7,00 to 10 5,5 11 25 10,00 to 13 7,5 15 25 13,00 to 18 11 20 40 18,00 to 25 15 28 40 23,00 to 32 18,5 34 63 30,00 to 40 22 40 63 38,00 to 50 25 47 80 0,63 to 1 50/1 30 55 80 " 60/1 37 66 115 " 80/1 45 80 185 " 100/1 55 100 185 " 125/1 75 128 185 " 150/1 90 156 265 " 200/1 132 224 400 " 250/1 160 280 400 " 300/1 Up to 63 A, circuit breakers are equipped with thermal overload and magnetic protection circuits rated for standard motors. * to be filled by MCC Supplier for type 2 co-ordination (please refer to section 7.2). The number of circuit breaker sizes will be limited to reduce spare part stock. POWER CONTROL CENTRES, Document Page Rev. MOTOR CONTROL CENTRES STD.002.U07 22/31 A 12. DIAGRAMS MCC single line diagrams in 2 versions : Either the emergency generator feeds the essential users through the normal busbar of the MCC and the load shedding of the other users is controlled by the PCS. Or the MCC is equipped with an emergency busbar for feeding the essential users from the emergency generator, the other users being connected to the normal busbar not fed from the emergency generator. Lafarge standard schematic diagrams of 5 types : K1 : motor one direction K2 : motor two directions KM : actuator 2 positions VS : variable speed drive (VSD installed inside the MCC) Q : circuit breaker supplying a package such as a crane panel, … For each schematic diagram following facilities shall be specified by following suffixes: E : emergency shut-down (pull-rope, push-button) I : current measurement J : power measurement S : speed monitor H : heavy start. Examples : Belt conveyor : K1 EIS Fan, Pmot > 30 kW, direct start : K1 IH Kiln motor : VS I POWER CONTROL CENTRES, Document Page Rev. MOTOR CONTROL CENTRES STD.002.U07 23/31 A MOTOR CONTROL CENTRE Typical single line diagram without LV emergency supply Main Horizontal Busbars MEASURING MODULE (KY) I I I I I I I I I PE MOTOR STARTER MODULES PACKAGE FEEDING ESSENTIAL MOTOR CONTROL CENTRES POWER CONTROL CENTRES, CONSUMERS By- Pass 400V 3 CAPACITOR BANK Auxiliary INCOMING FEEDER STEP REGULATION ACCORDING TO PF & LOAD Transformer (TF) TN-S NETWORK 230Vac NEUTRAL CONDUCTOR 230Vac UPS (UP) NOT DISTRIBUTED Document STD.002.U07 DISTRIBUTION TRANSFORMER (TF) MEDIUM/LOW VOLTAGE Page 24/31 A Rev. MOTOR CONTROL CENTRE Typical single line diagram with LV emergency supply Main Horizontal Busbars Emergency Horizontal Busbars MEASURING MODULE (KY) I I I I I I I I I PE PE V MOTOR STARTER MODULES PACKAGE FEEDING ESSENTIAL MOTOR CONTROL CENTRES POWER CONTROL CENTRES, CONSUMERS By- Pass 400V 3 3 CAPACITOR BANK Auxiliary INCOMING FEEDER STEP REGULATION ACCORDING TO PF & LOAD Transformer TN-S NETWORK (TF) 230Vac 230Vac NEUTRAL CONDUCTOR UPS (UP) NOT DISTRIBUTED Document STD.002.U07 DISTRIBUTION TRANSFORMER (TF) MEDIUM/LOW VOLTAGE G EMERGENCY GENERATOR Page 25/31 3 A Rev. MOTOR CONTROL CENTRE MCC 316MC13-VSD Kiln Downstream (example) Note: fast fuses for VSD protection Busbar 1 400V Busbar 2 IM-Insulation Monitoring 3 3 IM IM Fast fuses 3 3 Surge arrester MOTOR CONTROL CENTRES POWER CONTROL CENTRES, 1000A 1000A MV/LV transformer M M M M M M M M M M M M M M M M Document STD.002.U07 3*30kW 3*30kW 3*30kW 3*30kW 75kW 132kW 318HE01MT10 318HE01MT13 318HE01MT16 318HE01MT19 316AB13MT10 75kW 317FA05MT10 110kW 318HE01MT11 318HE01MT14 318HE01MT17 318HE01MT20 317FA03MT10 317FA07MT10 318HE01MT12 318HE01MT15 318HE01MT18 318HE01MT21 Page 26/31 A Rev. 400 V 230V ac +24V dc MOTOR CONTROL CENTRE 0V Typical schematic diagram - Motor 1 direction - K1 type -Q11 -Q12 Drawer or Plate I/O Compartment Digital output -Q1 Precut-off Yellow Green Red -KA1 To Q1 Trip 12 10 C1 Start Command Available Failure Running -KM1 Digital input 1 AV Availability -F1 7 B1 Feedback 4 L1 Local Start 3 LS Local Stop -Q1 2 -KA1 -KB -KM1 -F1 HS Emergency Shut-Down Trip -KB -KM1 H Heavy start (if any) I Current measure or / Motor Operating Mode : J Power measure Choice of Sequential/ Local mode is made by operator 1 3 4 2 on the Operator Station Field MOTOR CONTROL CENTRES POWER CONTROL CENTRES, 1 3 4 Visible Cut-off Switch L1 Marshalling Board LS Pre-Cut off Digital input Document 3 Padlocks S Speed monitor STD.002.U07 2 7 8 XS Speed switch Cable- Loop HS E Emergency Shut-Down XXnn Other machine sensors pull rope 24V dc M (if applicable) Analogue input 3 Page 27/31 YI Motor Current or Power A Rev. 400 V 230V ac +24V dc MOTOR CONTROL CENTRE 0V Typical schematic diagram - Motor 2 directions - K2 type Drawer or Plate I/O Compartment -Q11 -Q12 Digital output -Q1 Precut-off Yellow Green Green Red -KA2 -KA1 12 10 C1 Start Command Direction 1 To Q1 Trip 13 11 C2 Start Command Direction 2 Available Failure Running Direction 1 Running Direction 2 -KM1 -KM2 Digital input 1 AV Availability -F1 7 B1 Feedback Direction 1 8 B2 Feedback Direction 2 -KM2 -KM1 -Q1 -KB -KM1 -KM2 -F1 Trip -KA1 -KA2 3 -KB -KM1 -KM2 LS Local Stop 4 L1 Local Start Direction 1 5 L2 Local Start Direction 2 H Heavy start (if any) 2 HS Emergency Shut-Down I Current measure or / Motor Operating Mode : J Power measure Choice of Sequential/ Local mode is made by operator 1 4 5 10 11 3 2 on the Operator Station Field MOTOR CONTROL CENTRES POWER CONTROL CENTRES, 1 4 5 10 11 Visible Cut-off Switch L1 L2 3 LS Marshalling Board Pre-Cut off Document 3 Padlocks 2 STD.002.U07 7 8 Digital input Cable- Loop HS E Emergency Shut-Down S Speed monitor pull rope (if applicable) XS Speed switch M XXnn Other machine sensors 3 24V dc Page 28/31 Analogue input YI Motor Current or Power A Rev. 400 V 230V ac +24V dc MOTOR CONTROL CENTRE 0V Typical schematic diagram - Actuator 2 positions - KM type Drawer or Plate I/O Compartment Digital output -Q1 Precut-off Yellow Green Green Red -KA2 -KA1 12 10 C1 Start Command Direction 1 To Q1 Trip (open) 13 11 C2 Start Command Direction 2 (close) Available Failure Direction 1 Direction 2 Running Running -KM1 -KM2 Digital input 1 AV Availability 7 -F1 B1 Feedback Direction 1 8 B2 Feedback Direction 2 14 XZ10 Position 1 switch (open) -KM2 -KM1 15 - Q1 XZ20 Position 2 switch (close) -KB -KM1 -KM2 -F1 Trip 9 -KA1 -KA2 XX10 Torque switch (if any) 3 -KB -KM1 -KM2 LS Local Stop 4 L1 Local Start Direction 1 (open) 5 L2 Local Start Direction 2 (close) Motor Operating Mode : Choice of Sequential/ Local mode is made by operator 1 4 5 10 11 9 3 on the Operator Station Field Actuator MOTOR CONTROL CENTRES POWER CONTROL CENTRES, XZ10 XZ20 Position1 Position2 1 4 5 10 11 Marshalling Board 9 Visible Cut-off Switch L1 L2 Torque 3 switch Digital input XXnn Other machine sensors LS 24V dc Pre-Cut off Analog input Document 3 Padlocks STD.002.U07 YZ10 Position Feedback 7 8 Cable- Loop Analogue output M ZC Position set point Page 29/31 3 A Rev. 400 V 230V ac 230V UPS +24V dc MOTOR CONTROL CENTRE 0V Typical schematic diagram - Motor speed variation - VS type Drawer or Plate I/O Compartment -Q11 -Q13 -Q12 Digital output -Q1 Precut-off Yellow Green Red -KA1 Note: fast fuses for VSD protection To Q1 Trip 12 10 C1 Start Command -KM1 Available Failure Running Digital input 1 AV Availability -F1 7 B1 Feedback 4 L1 Local Start 3 LS Local Stop 16 -KA1 - Q1 LU Local Speed-up -KA1 -KB -KM1 -F1 6 Trip LD Local Speed-down -KB -KM1 2 HS Emergency Shut-Down -C1 Motor Operating Mode : Choice of Sequential/ Local mode is made by operator on the Operator Station 1 3 4 16 6 2 MOTOR CONTROL CENTRES POWER CONTROL CENTRES, Field Fieldbus to PCS controller 1 3 4 16 6 Visible Cut-off Switch L1 LU LD Marshalling Board LS Analog input Document Pre-Cut off STD.002.U07 YI Motor Current or Power 3 Padlocks 2 YS Speed feedback 7 8 To VSD inside MCC Cable- Loop HS E Emergency Shut-Down Analogue output pull rope Page 30/31 (if applicable) SC Speed set-point M 3 A Rev. 400 Vac MOTOR CONTROL CENTRE Typical schematic diagram - Package circuit breaker - Q type Drawer or Plate I/O Compartment Digital input 24V dc Q1 AV Availability / I Current measure or J Power measure Field MOTOR CONTROL CENTRES POWER CONTROL CENTRES, Marshalling Board Visible Cut-off Switch Document STD.002.U07 Analogue input 3 Padlocks YI Current or Power Page 31/31 PACKAGE A Rev.
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