TECHNICAL SPECIFICATION
LOW VOLTAGE SWITCHGEAR AND CONTROLGEAR
ASSEMBLIES (AMENDMENTS/SUPPLEMENTS TO IEC
60439-1)
DEP 33.67.01.31-Gen.
November 2006
DESIGN AND ENGINEERING PRACTICE
This document is restricted. Neither the whole nor any part of this document may be disclosed to any third party without the prior written consent of Shell Global
Solutions International B.V., The Netherlands. The copyright of this document is vested in this company. All rights reserved. Neither the whole nor any part of this
document may be reproduced, stored in any retrieval system or transmitted in any form or by any means (electronic, mechanical, reprographic, recording or otherwise)
without the prior written consent of the copyright owner.
DEP 33.67.01.31-Gen.
November 2006
Page 2
PREFACE
DEPs (Design and Engineering Practice) publications reflect the views, at the time of publication, of:
Shell Global Solutions International B.V. (Shell GSI)
and/or
Shell International Exploration and Production B.V. (SIEP)
and/or
other Shell Service Companies.
They are based on the experience acquired during their involvement with the design, construction, operation and
maintenance of processing units and facilities, and they are supplemented with the experience of Shell Operating Units.
Where appropriate they are based on, or reference is made to, international, regional, national and industry standards.
The objective is to set the recommended standard for good design and engineering practice applied by Shell companies
operating an oil refinery, gas handling installation, chemical plant, oil and gas production facility, or any other such
facility, and thereby to achieve maximum technical and economic benefit from standardization.
The information set forth in these publications is provided to Shell companies for their consideration and decision to
implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at
each locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units to adapt the
information set forth in DEPs to their own environment and requirements.
When Contractors or Manufacturers/Suppliers use DEPs they shall be solely responsible for the quality of work and the
attainment of the required design and engineering standards. In particular, for those requirements not specifically
covered, the Principal will expect them to follow those design and engineering practices which will achieve the same
level of integrity as reflected in the DEPs. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting
from his own responsibility, consult the Principal or its technical advisor.
The right to use DEPs is granted by Shell GSI, in most cases under Service Agreements primarily with Shell companies
and other companies receiving technical advice and services from Shell GSI or another Shell Service Company.
Consequently, three categories of users of DEPs can be distinguished:
1)
Operating Units having a Service Agreement with Shell GSI or other Shell Service Company. The use of DEPs
by these Operating Units is subject in all respects to the terms and conditions of the relevant Service
Agreement.
2)
Other parties who are authorized to use DEPs subject to appropriate contractual arrangements (whether as part
of a Service Agreement or otherwise).
3)
Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2)
which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said
users comply with the relevant standards.
Subject to any particular terms and conditions as may be set forth in specific agreements with users, Shell GSI
disclaims any liability of whatsoever nature for any damage (including injury or death) suffered by any company or
person whomsoever as a result of or in connection with the use, application or implementation of any DEP, combination
of DEPs or any part thereof, even if it is wholly or partly caused by negligence on the part of Shell GSI or other Shell
Service Company. The benefit of this disclaimer shall inure in all respects to Shell GSI and/or any Shell Service
Company, or companies affiliated to these companies, that may issue DEPs or require the use of DEPs.
Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall
not, without the prior written consent of Shell GSI, be disclosed by users to any company or person whomsoever and
the DEPs shall be used exclusively for the purpose for which they have been provided to the user. They shall be
returned after use, including any copies which shall only be made by users with the express prior written consent of
Shell GSI. The copyright of DEPs vests in Shell GSI. Users shall arrange for DEPs to be held in safe custody and Shell
GSI may at any time require information satisfactory to them in order to ascertain how users implement this
requirement.
All administrative queries should be directed to the DEP Administrator in Shell GSI.
DEP 33.67.01.31-Gen.
November 2006
Page 3
TABLE OF CONTENTS
PART 1
1.1
1.2
1.3
1.4
1.5
1.6
INTRODUCTION ........................................................................................................4
SCOPE........................................................................................................................4
DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS .........4
DEFINITIONS .............................................................................................................4
SUMMARY OF CHANGES SINCE PREVIOUS EDITION .........................................5
CROSS-REFERENCES .............................................................................................6
COMMENTS ON THIS DEP .......................................................................................6
PART 2
3.
4.
4.1
4.2
4.7
5
5.1
5.3
6.
6.1
6.2
6.3
7.
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.10
8.
8.1
8.2
8.3
AMENDMENTS/SUPPLEMENTS TO IEC 60439-1...................................................7
CLASSIFICATION OF ASSEMBLIES ........................................................................7
ELECTRICAL CHARACTERISTICS OF ASSEMBLIES.............................................7
RATED VOLTAGES ...................................................................................................7
RATED CURRENT .....................................................................................................7
RATED DIVERSITY FACTOR ....................................................................................8
INFORMATION TO BE GIVEN REGARDING THE ASSEMBLY ...............................8
NAMEPLATES ............................................................................................................8
INSTRUCTIONS FOR INSTALLATION, OPERATION AND MAINTENANCE ..........9
SERVICE CONDITIONS...........................................................................................11
NORMAL SERVICE CONDITIONS ..........................................................................11
SPECIAL SERVICE CONDITIONS ..........................................................................11
CONDITIONS DURING TRANSPORT, STORAGE AND ERECTION.....................11
DESIGN AND CONSTRUCTION..............................................................................12
MECHANICAL DESIGN............................................................................................12
ENCLOSURE AND DEGREE OF PROTECTION ....................................................13
TEMPERATURE RISE .............................................................................................13
PROTECTION AGAINST ELECTRIC SHOCK.........................................................14
SHORT-CIRCUIT PROTECTION AND SHORT-CIRCUIT WITHSTAND
STRENGTH ..............................................................................................................14
SWITCHING DEVICES AND COMPONENTS INSTALLED IN ASSEMBLIES........16
INTERNAL SEPARATION OF ASSEMBLIES ..........................................................23
ELECTROMAGNETIC COMPATIBILITY .................................................................23
TEST SPECIFICATIONS..........................................................................................25
CLASSIFICATION OF TESTS..................................................................................25
TYPE TESTS ............................................................................................................25
ROUTINE TESTS .....................................................................................................26
PART 3
REFERENCES .........................................................................................................27
APPENDICES
APPENDIX 1
INTEGRATED MOTOR CONTROL SYSTEM (IMCS) ....................................29
Table A1.1
Matrix of typical IMCS features........................................................................42
DEP 33.67.01.31-Gen.
November 2006
Page 4
PART 1 INTRODUCTION
1.1
SCOPE
This DEP specifies requirements and gives recommendations for low voltage switchgear
and controlgear assemblies.
This DEP is a revision of the DEP of the same number dated January 1998.
Part 2 of this DEP amends and supplements IEC 60439-1 (1999 + A1: 2004), referring to
the same clause numbers. The additional requirements specified in this DEP are required
in order to:
a.
b.
c.
Make selections from the options given in IEC 60439-1,
Specify additional and more stringent requirements, as necessary, to operate and
maintain the gear in continuously operating plants,
Specify supplementary provisions required to make the gear suitable for operation in
the overall process control design.
Integrated Motor Control Systems (IMCS) when specified shall comply with Appendix 1.
The requirements specified apply to type-tested assemblies (TTA). For assemblies used as
sub-distribution systems, with incoming feeders protected by short-circuit current limiting
devices of a nominal current of maximum 400 A, less rigorous requirements can be
accepted. This is indicated in bold italic text under the specific headings, and with
reference to this clause for the above definition.
1.2
DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS
Unless otherwise authorised by Shell GSI, the distribution of this DEP is confined to Shell
companies and, where necessary, to Contractors and Manufacturers/Suppliers nominated
by them.
This DEP is intended for use in oil refineries, gas plants, chemical plants, exploration and
production facilities and supply/marketing installations.
When DEPs are applied, a Management of Change (MOC) process should be
implemented; this is of particular importance when existing facilities are to be modified.
If national and/or local regulations exist in which some of the requirements may be more
stringent than in this DEP the Contractor shall determine by careful scrutiny which of the
requirements are the more stringent and which combination of requirements will be
acceptable as regards safety, environmental, economic and legal aspects. In all cases the
Contractor shall inform the Principal of any deviation from the requirements of this DEP
which is considered to be necessary in order to comply with national and/or local
regulations. The Principal may then negotiate with the Authorities concerned with the object
of obtaining agreement to follow this DEP as closely as possible.
1.3
DEFINITIONS
1.3.1
General definitions
The Contractor is the party which carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project or operation of a
facility. The Principal may undertake all or part of the duties of the Contractor.
The Manufacturer/Supplier is the party which manufactures or supplies equipment and
services to perform the duties specified by the Contractor.
The Principal is the party which initiates the project and ultimately pays for its design and
construction. The Principal will generally specify the technical requirements. The Principal
may also include an agent or consultant authorised to act for, and on behalf of, the
Principal.
DEP 33.67.01.31-Gen.
November 2006
Page 5
The word shall indicates a requirement.
The word should indicates a recommendation.
1.3.2
Specific definitions
Integrated
Motor Control
System (IMCS)
A system comprising control modules, central unit(s), a serial bus
connecting the control modules to the central unit and a
communication facility enabling connection of the central unit to a
distributed control system (DCS) and/or a Supervisory Control
and Data Acquisition System (SCADA).
Panel
A constructional unit of a (multi-) cubicle type assembly between
two successive vertical delineations.
Requisition
is one of the following:
DEP 33.67.01.93-Gen. (requisition for LV switchboard).
DEP 33.67.01.94-Gen. (requisition for lighting distribution board).
NOTE:
1.4
DEP 33.67.01.80-Gen. (schedule for LV switchboard) is normally
attached to the requisition.
Restarting relay
(RR)
A relay which initiates the re-closure of a motor circuit under
predetermined conditions, after a voltage depression or
interruption.
Section
A constructional unit consisting of a number of panels connected
to a continuous busbar system.
Sectionaliser
unit
A mechanical switching device to connect the busbar of two
sections.
Skeleton
Compartment
A spare compartment for later completion but so equipped that
completion can take place safely without the need to de-energise
the switchboard or any other panel.
Time delayed
restarting relay
(TMR)
A time delayed relay which initiates a delayed re-closure of a
motor circuit controlled by the process control system, under
predetermined conditions, after a voltage depression or
interruption.
SUMMARY OF CHANGES SINCE PREVIOUS EDITION
-
IEC numbers have been updated by adding prefix 6X;
-
Reference made to newly developed IECs, and withdrawn IECs have been deleted;
-
EMC requirements in latest version of IEC 60439-1 implemented;
-
Appendix 1 on IMCS modified in order to:
• make it a specification describing the functional requirements;
• include the possibility to select specific features and extend the IMCS as required;
• bring it more in line with the commercially available systems.
-
A sheet has been added to the requisition specifying the features of the IMCS.
DEP 33.67.01.31-Gen.
November 2006
Page 6
1.5
CROSS-REFERENCES
Where cross-references to other parts of this DEP are made, the referenced clause number
is shown in brackets. Other documents referenced by this DEP are listed in (Part 3).
1.6
COMMENTS ON THIS DEP
Comments on this DEP may be sent to the DEP Administrator at standards@shell.com.
Shell staff may also post comments on this DEP on the Surface Global Network (SGN)
under the Standards folder.
DEP 33.67.01.31-Gen.
November 2006
Page 7
PART 2 AMENDMENTS/SUPPLEMENTS TO IEC 60439-1
In this part, clauses of IEC 60439-1 are amended or supplemented, or new clauses are
added. Clauses of IEC 60439-1 that are not mentioned shall remain applicable as written.
3.
CLASSIFICATION OF ASSEMBLIES
Add to this clause:
Although this standard is mainly concerned with fully withdrawable gear of (multi-) cubicle
type assemblies for indoor installation, it shall also apply to fixed and semi-withdrawable
cubicle type assemblies and combinations thereof, and to multi-box type assemblies and
assemblies located outdoors.
Assemblies intended to be installed in hazardous areas (IEC 60079-10) shall meet the
additional requirements specified by the Principal
4.
ELECTRICAL CHARACTERISTICS OF ASSEMBLIES
Add to this clause:
During normal system operation and under steady-state conditions, the supply voltage shall
not deviate from the rated voltage by more than 5 % and the system frequency shall not
deviate from the rated frequency by more than 2 %.
Transient voltage deviations during e.g. motor or group motor starting/reacceleration shall
be such as to maintain a minimum of 90 % and shall be not more than 110 % of rated
voltage on switchgear busbars.
Switchgear to be installed on mobile and fixed offshore installations shall be suitable for
continuous operation from a supply which is subject to voltage waveform distortions
caused by thyristor controlled loads. In the quotation stage, the Principal shall advise the
percentage Total Harmonic Distortion that has to be taken into account.
Deviation from the supply characteristics, if any, shall be stated on the requisition.
4.1
RATED VOLTAGES
Add to this clause:
The assembly shall be suitable to form part of a system with coordinated insulation values
in accordance with IEC 60664-1, overvoltage category IV, and shall be type tested
accordingly.
The overvoltage category of assemblies with a rated voltage in excess of 600 V shall be as
a minimum category III.
4.2
RATED CURRENT
Add to this clause:
Unless otherwise specified in the requisition, the assembly shall be arranged for a TN-S
power system, i.e. with separate neutral and protective busbars throughout the system.
The main busbars shall be rated for the nominal current over the entire length of the
assembly and shall not be rated lower than the incoming and sectionaliser units.
DEP 33.67.01.31-Gen.
November 2006
Page 8
4.7
RATED DIVERSITY FACTOR
Add to this clause:
For temperature rise tests or temperature rise calculations, a diversity factor of 1.0 shall be
applied for each switchboard panel containing only one functional unit. If a panel contains
two or more functional units, the rated diversity factor applied shall be not less than 0.9
when considering the circuit loads as known at the time of final inspection at the
Manufacturer’s works. Spare circuits and skeleton compartments shall be considered as
being loaded to 90 % of their rated current.
Where IMCS is specified, the equipment shall be included in the temperature test.
This supplement does not apply to assemblies used as sub-distribution systems as
defined in (Part 1; 1.1), to which the original clause of IEC 60439-1 shall apply.
5
INFORMATION TO BE GIVEN REGARDING THE ASSEMBLY
5.1
NAMEPLATES
Add to this clause:
Nameplates including circuit labels, instruction and warning plates and caution notes shall
be made of durable, corrosion resistant material.
Add new clause:
5.1.1
General equipment nameplate
The following information shall be given on the general equipment nameplate, which shall
be mounted on the front of the assembly, e.g. on the sectionaliser or incoming feeder:
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
Manufacturer’s name or trademark;
Type designation;
Purchase order number;
Year of manufacture;
Rated voltage;
Rated frequency;
Rated current of busbar system;
Rated voltage of auxiliary circuits (if applicable);
Rated peak and short time withstand current and withstand time;
Degree of protection;
Form of internal separation.
The above information together with the other information of IEC 60439-1 clause 5.1 shall
be given in the relevant documents of the Manufacturer.
Where applicable, other markings shall be provided on the assembly (e.g. CE, ATEX)
Add new clause:
5.1.2
Circuit labels
Each circuit of the assembly shall be provided with the following circuit identification labels:
a. Circuit identification tag number in accordance with standard drawing S 67.021. The
circuit labels shall be installed on the front of the fixed and the removable part of a
withdrawable or removable unit and repeated at the main and auxiliary cable
terminations which are not clearly identifiable from the physical layout, e.g. cable
compartments at the rear or bottom of the assembly.
b. Identification number of connected equipment or circuit destination as specified in
DEP 33.67.01.80-Gen.
DEP 33.67.01.31-Gen.
November 2006
Page 9
Add new clause:
5.1.3
Synoptic diagram
Assemblies shall be provided with a durable one-line synoptic diagram, indicating the
busbar circuit and the specific function of the different compartments.
Synoptic diagrams are not required if the busbar system and the branch circuits can be
viewed via transparent covers.
Add new clause:
5.1.4
Instruction plates
If the operating sequence or procedure of certain equipment items in the assembly is not
evident, e.g. mechanical interlocking features, instruction plates shall be provided fixed
near the point of operation. The instruction shall be given as far as possible in a pictorial
manner.
Add new clause:
5.1.5
Warning plates, caution notices
In locations where dangerous situations may inadvertently be created, warning plate(s) or
caution notice(s) shall be installed, identifying the danger point(s). This may be either in a
compartment or on the outside of an assembly.
5.3
INSTRUCTIONS FOR INSTALLATION, OPERATION AND MAINTENANCE
Add to this clause:
The Manufacturer shall supply at least the following drawings/documents in the quantities
and at the times stated in form DEP 40.10.01.93-Gen, attached to the requisition:
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
Final single-line diagram *,
Schematic diagrams of all different types of circuits,
Documentation as specified in Appendix 1 (in case of IMCS only),
Final assembly arrangement drawing showing main circuits, main dimensions, panel
layout, floor plan and shipping sections *,
Minimum clearances around the assemblies for ventilation and safety during operation
and maintenance *,
Total mass of the assembly and of the individual shipping sections *,
Transport, installation, commissioning, operation and maintenance instructions, limited
and specific to the assembly and its components,
Instructions of measures to be taken, if any, with regard to EMC associated with the
installation, operation and maintenance of the assembly,
List of recommended spare parts and SPIR forms (see DEP 70.10.90.11-Gen.),
List of applicable type test certificates,
Test report of the final routine testing.
NOTE*:
Items marked * may be combined, provided all information indicated above is included.
All documents shall show the relevant order number, item and Manufacturer’s references,
and shall be formatted and distributed as specified in the purchasing documents.
Documents shall also be provided on a PC readable device (e.g. CD-ROM), unless
otherwise specified by the Principal.
Assemblies supplied in transport units shall have these units clearly marked to facilitate
assembly at site.
Erection instructions and any special tools required for erection and maintenance shall form
an integral part of the order and shall be packed with the equipment.
DEP 33.67.01.31-Gen.
November 2006
Page 10
The Manufacturer shall provide with the quotation preliminary arrangement drawings and
details of component ratings, e.g. by filling in the appropriate sections of
DEP 33.67.01.80-Gen. (schedule for LV switchboard), and all other information as specified
further on in this DEP.
The language used shall be as specified in the requisition.
DEP 33.67.01.31-Gen.
November 2006
Page 11
6.
SERVICE CONDITIONS
6.1
NORMAL SERVICE CONDITIONS
Add to this clause:
The actual service conditions shall be specified in the requisition if they are more onerous
than those stated in IEC 60439-1.
The requisition shall specify the location (land or offshore installation) where the assembly
will be installed. It also specifies whether the assembly will be installed indoors or outdoors.
6.1.2.3
Pollution degree
Add to this clause:
Unless otherwise specified in the requisition, the assembly and the components installed
therein shall be suitable for use in a pollution degree 3 environment. However, the air will
be laden with dust, salt and/or sulphur as encountered in the petrochemical industries or in
oil/gas fields.
6.2
SPECIAL SERVICE CONDITIONS
Add to this clause:
Any special service condition that the switchgear may be required to withstand in its
operational location shall be specified on the requisition.
Equipment installed on mobile and fixed offshore installations shall be unaffected by
vibration and shock. The equipment for these applications shall be tested according to
IEC 61892–3:1999, Table 9, Item 9.
Unless otherwise specified, the switchboard shall be suitable for installation in a
non-hazardous area as defined in IEC 60079-10.
6.3
CONDITIONS DURING TRANSPORT, STORAGE AND ERECTION
Add to this clause:
The requisition shall specify any special conditions that may arise, e.g. shock and vibration
and/or extreme temperatures.
DEP 33.67.01.31-Gen.
November 2006
Page 12
7.
DESIGN AND CONSTRUCTION
7.1
MECHANICAL DESIGN
7.1.1
General
Add to this clause:
The assemblies shall be designed for continuous operation at full load for at least 90,000 h
without maintenance which would require the main busbars and the distribution busbars
(dropper system) to be de-energised. When operating under the specified service
conditions, the main and distribution busbars including their connections shall not require
maintenance during the lifetime of the assembly.
NOTE:
1) De-energising of the main busbar and distribution busbars after 90,000 h may be required, e.g. to
inspect and clean the compartments.
2) Operation of switching devices may be required within the period of 90,000 h as mentioned above.
For non-essential switchgear this may lead to de-energising of the busbar. Assemblies in vital and
essential service will normally have dual feeders and bussection switches to cater for continuous
operation, even when one of these switches is operated.
The assemblies shall have a design lifetime of at least 25 years, under the service
conditions specified and maintained according to the Manufacturer's recommendation.
Where IMCS is specified, the lifetime of this system shall be aligned with the lifetime of the
assembly (see also Appendix 1).
All structural work shall be adequately protected against corrosion. Frame and partitions
may be of galvanised steel without a further paint coating. Those parts/covers requiring
painting shall be properly pre-treated before the final coat(s) of oil resistant finishing paint is
(are) applied. The Manufacturer’s standard colour is acceptable. If a Manufacturer does not
have a standard colour, light grey is preferred for the external surface.
Assemblies shall comprise one or more sections of busbars to which incoming and
outgoing units are connected. Busbar sections shall be linked through sectionaliser units.
In addition to the outgoing units specified in the requisition or schedule, spare skeleton
compartments shall be included in each switchboard. The number of skeleton
compartments shall be 10 % of each size of outgoing units of which at least three units are
installed. They shall be allocated to the switchboard sections in accordance with the actual
load distribution and the maximum load that can be accommodated shall be taken into
account. A skeleton compartment shall be equipped so that completion at its maximum
capacity can take place safely without the need to de-energise the switchboard or any other
panel.
7.1.3
Terminals for external conductors
Add to this clause:
In view of the substantial cable derating that is normally applied, adequate terminals and
cable termination space shall be provided for the main cabling. Details on size and type of
cable and its conductors shall be given in the Schedule for LV Switchboard.
For main incoming and outgoing power circuit cabling, terminals allowing the conductors to
be connected without the use of cable lugs of any type should be used. Adequate bracing
and support for the cables shall be provided to avoid unrestrained movement under short
circuit conditions.
Individual terminals shall be provided for each conductor of external auxiliary cables. These
terminals shall be of the non-loosening wedge type or cage type construction, obviating the
use of cable lugs. They shall be constructed in such a way that direct contact between
screw, bolt or nut and conductor is avoided.
NOTE:
For the termination of internal control wiring, push-on connections with insulation support of the
compression type may be used.
DEP 33.67.01.31-Gen.
November 2006
Page 13
Terminals shall be identified in accordance with the related wiring diagrams. The layout
shall be consistent and logical. Unless otherwise specified, terminal arrangements for the
control of motors shall be in accordance with drawing S 67.004.
As a standard, assemblies shall have facilities for the entry of cables from below. If top
entry is required this shall be stated on the requisition. Cable entries, support facilities for
cable clamping, and earthing facilities shall be provided suitable for the type, size and
number of cables as specified.
Vertical cable compartments, where provided, shall provide sufficient space to satisfy the
bending radii of the specified cables.
NOTE:
For main assemblies cable compartments of form 3b, an effective width of 300 mm is generally
sufficient. For cable compartments of form 4 switchgear, 250 mm is generally sufficient.
Cable glands or metal gland plates should only be included if specified in the requisition.
Gland plates and glands for single core cables shall be of non-magnetic material. In the
case of single core cables with armour and/or lead sheathing, the requirement for special
glands which allow for insulation between the armour/lead sheath and gland plate shall be
specified in the requisition.
7.2
ENCLOSURE AND DEGREE OF PROTECTION
Add to this clause:
Switchgear assemblies shall be completely enclosed, self-supporting and suitable for floor
or wall mounting, in multi-cubicle or multi-box type structures. The floor shall not be
considered as being part of the enclosure.
Details of specific installation requirements for e.g. offshore facilities shall be specified by
the Principal
Cover bolts or nuts shall be retained in place when undone (captive bolts and nuts).
The degree of protection as defined in IEC 60529 for any assembly shall be:
-
For indoor use (in enclosed buildings)
For outdoor use (protected by e.g. rain canopy)
NOTE:
IP 41
IP 55
Outdoor switchgear shall be provided with a rain/sun canopy.
The requirement for anti-condensation heating shall be specified in the requisition.
NOTE:
Space heaters shall be included in the quotation as an option, if they are not specified in the
requisition but the Manufacturer recommends their installation.
If anti-condensation heating is required inside the assembly, it shall be supplied from a
separate source connected between system phase and neutral. The heating system of
each section shall be separately protected and switched for isolation purposes by means of
a miniature circuit breaker in combination with an earth leakage protecting device of 30 mA
sensitivity. When the heating system is live, this shall be indicated by means of a
prominently situated red LED. The heating system shall be designed in such a way that the
heat is adequately distributed over all functional units.
7.3
TEMPERATURE RISE
Add to this clause:
The temperature rise limits as given in Table 2 shall not be exceeded when the assembly is
fully loaded in accordance with the diversity factors as given in clause 4.7 of IEC 60439-1
as amended/supplemented by this DEP.
The temperature rise limits for assemblies operating in mean ambient air temperatures
higher than 35 °C shall be agreed with the Principal at the quotation stage.
NOTE:
Particular attention shall be paid to electronic components, e.g. IMCS if installed.
DEP 33.67.01.31-Gen.
November 2006
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7.4
PROTECTION AGAINST ELECTRIC SHOCK
Add to this clause:
All switchgear components requiring maintenance shall be easily accessible. All
components in wall or back-to-back mounted switchgear shall be accessible from the front
only.
Exposed parts within the assemblies that have to be accessible during normal operation,
maintenance or equipping of spare compartments, shall either not be live in the opened
position or shall be protected to a degree of protection of at least IP 2X.
NOTE:
The terminals of the incoming and sectionaliser switching devices can be live when the device is in the
off position. Consequently these terminals shall always be protected to a degree of at least IP 2X.
HBC fuses and associated fuse carriers shall only be accessible when they are fully
isolated or when they offer a degree of protection to live parts of at least IP 2X when the
fuses are inserted, have been withdrawn or are being withdrawn.
Terminals of equipment installed on a compartment door and which can be live when the
door is opened shall be shrouded to a degree of protection of at least IP 2X.
Compartment doors or covers shall be interlocked to prevent opening when the isolating
switch is in the ‘ON’ position. The isolating device shall only be operable when the door is
closed and when the withdrawable unit is in the inserted position.
The above paragraphs do not apply to assemblies used as sub-distribution systems
as defined in (Part 1; 1.1) provided that all live parts inside the compartment have a
degree of protection of at least IP 2X.
When a withdrawable unit has been removed from the assembly, the live parts inside the
fixed compartment shall be protected against touch, with a degree of protection of at least
IP 2X. Where shutters are fitted to comply with the above requirement, they shall be
mechanically operated by the movement of the withdrawable unit and not be dependent on
gravity or springs.
Each set of shutters shall be capable of being individually operated and padlockable in the
closed position. Shutters shall be marked as follows:
‘BUSBAR’ on shutters covering busbars,
‘INCOMING SUPPLY’ on shutters covering incoming feeder cables,
‘CIRCUIT’ on shutters covering outgoing feeder cables.
If a test position is provided (partly withdrawn unit), the degree of protection shall be at least
IP 2X.
Interlock systems shall be of a mechanical lever type and shall not rely on the operation of
springs or gravity.
All practicable measures shall be taken to prevent danger to personnel working on a
disconnected functional unit with adjacent units still in operation. Parts likely to be removed
for maintenance shall have retainable fastening means (e.g. captive screws).
7.5
SHORT-CIRCUIT PROTECTION AND SHORT-CIRCUIT WITHSTAND STRENGTH
7.5.1
General
Add to this clause:
In the event of an internal fault in a functional unit, the damage shall be confined to that
unit, so that the busbar system and all other functional units remain fit for further service.
Likewise, an internal fault in a dropper system shall be confined to the associated panel, so
that the busbar system and the other panels of the assembly remain fit for further service.
With regard to safety of personnel, assemblies shall be tested with respect to their ability to
withstand internal arcing. The Manufacturer shall confirm the successful assessment in
accordance with IEC TR 61641, Criteria 1 to 5.
DEP 33.67.01.31-Gen.
November 2006
Page 15
Test reports should be made available in the quotation stage.
The above paragraphs do not apply to assemblies used as sub-distribution systems
as defined in (Part 1; 1.1), to which the original clause of IEC 60439-1 shall apply.
The prospective short-circuit current shall be stated in the requisition and will be based on
parallel operations of all supplies which can be paralleled during normal operations and
temporary operations during change-over periods; it will also include the contribution that
can be expected from the connected load.
NOTE:
7.5.3
For sub-distribution assemblies the prospective short-circuit current will be limited by the supply fuse
rating.
Relationship between peak and r.m.s. values of short circuit current
Add to this clause:
The values of the factor ‘n’, giving the relation between peak and r.m.s. value of the short
circuit current, shall be as stated in Table 4. An upward adjustment may be required if a
power factor of lower value than standard is expected. If applicable, this shall be stated in
the requisition.
7.5.4
Co-ordination of short-circuit protective devices
Add to this clause:
In motor starter units, the co-ordination between starter and protective device shall comply
with type “2” as specified in IEC 60947-4-1. This generally implies that a starter is
sufficiently protected by the short-circuit protection so that no damage will occur to the
starter in case of a through-going fault current.
Type test reports shall be made available on request.
7.5.5
Circuits within an assembly
Add to this clause:
The busbar system, which under the terms of this specification includes all live conducting
parts from the incoming terminals of the assembly up to the circuit protection inside the
single outgoing functional units, shall be considered as being a ‘fault free zone’. The
arrangements shall be such that a fault in this zone shall be virtually impossible under all
conditions (see also 7.6.1.1).
The short circuit protection device inside each outgoing functional unit shall be connected
directly to the busbars.
This supplement does not apply to assemblies used as sub-distribution systems as
defined in (Part 1; 1.1), to which the original clause of IEC 60439-1 shall apply.
DEP 33.67.01.31-Gen.
November 2006
Page 16
7.6
SWITCHING DEVICES AND COMPONENTS INSTALLED IN ASSEMBLIES
7.6.1
Selection of switching devices and components
Add to this clause:
All components shall be standardised as far as practical.
The connections of the auxiliary circuits of withdrawable units shall be of the
plug-and-socket type, automatically operated by the unit.
Circuits, components, wiring and terminal arrangements shall be installed in accordance
with the relevant standard drawings of group S 67.
Add new clause:
7.6.1.1
Busbar system
The phase, neutral and earth busbars shall be of hard or medium hard drawn, high
conductivity copper.
The phase and neutral busbars shall be located in the top compartments of the switchboard
or alternatively in the rear of the switchgear. In the latter case the design shall be such that
access is provided to the busbar joints via a firmly secured cover that is at least IP 4X and
has captive bolts/nuts.
The busbar system shall be accessible for construction and maintenance duties.
The neutral bar shall be insulated from earth and shall be extended to all compartments
reached by the phase busbars. In three phase switchboards carrying a balanced load under
normal conditions, the neutral busbar shall have a cross section of at least 50 % of that of
the phase busbars with a minimum of 16 mm². For busbar systems with a cross section
below 16 mm² the neutral conductor shall have the same cross section as the phase
conductors.
The earth bar shall be located in the top or bottom compartments over the whole length of
the switchboard and in all cable riser compartments (top to bottom) and shall be easily
accessible. Sufficient connection points with adequate terminating facilities shall be
provided for terminating the cable earth leads and the external earth connections. For the
termination of external earth connections the earth bar shall be provided with an M10 bolt
near the bottom of each outgoing cable compartment and at the incoming panels.
In the busbar compartment the phase busbars shall be fully insulated. The insulation shall
be type tested for withstanding at least an AC test voltage of 2 kV for a period of 60 s
applied between the bar and an aluminium foil wrapped closely around the insulation over a
length of at least one metre.
The distribution busbars (droppers, phase and neutral) shall have full segregation by
insulated material. The insulation of the busbar joints and busbar to dropper joints shall be
of equal quality to that of the main bars and shall be removable and easily replaceable for
inspection.
The comparative tracking index (CTI as defined in IEC 60112) of the insulating material
used for the supports and insulation of the busbar and dropper systems shall be at least
300. The CTI for the insulation materials used for the components protected by the
short-circuit protective devices in the outgoing functional units shall be at least 175.
The neutral busbar may be uninsulated in the busbar compartment but shall be insulated in
all other compartments with the same insulation level as the phase conductors.
This new clause does not apply to assemblies used as sub-distribution systems as
defined in (Part 1; 1.1).
DEP 33.67.01.31-Gen.
November 2006
Page 17
Add new clause:
7.6.1.2
Incoming and sectionaliser units
Incoming and sectionaliser units shall be mounted in separate compartments and shall be
provided with independent manually operated air break switches (fault make, load break) or
circuit breakers. When circuit breakers are specified they shall be mounted in separate
panels. The utilisation category for the manually operated switches as defined in
IEC 60947-3 shall be at least AC 22 for switching devices up to and including 630 A and
may be AC 21 for devices with higher current ratings. The utilisation category for circuit
breakers as defined in IEC 60947-2 shall be category A, unless otherwise specified.
Switching devices shall switch all phases or poles (i.e. 4-pole type for 3 phase + neutral
systems). For balanced systems, the neutral pole current rating shall be not less than
specified for the neutral busbars (7.6.1.1).
The switching devices shall have padlock facilities with minimum 5 mm hasp diameter in
the ‘OFF’ position. Key interlock systems between incoming and sectionaliser units shall
only be provided when specified.
Each incoming unit shall be provided with one voltmeter, connected to the busbar side
between L1 and L3 phase, and one ammeter in the L2 phase. The meters shall be suitably
scaled in actual values for the rated voltage and current. As an alternative, the Principal
may specify a multi-functional digital measuring device in place of the analogue metering.
This shall be specified on the requisition.
The metering supply to volt and watt-hour meters etc. shall be protected with HBC-type
fuses of the fully insulated pattern fixed directly to the busbar system. A second set of fuses
or miniature circuit breakers, discriminated with the HBC-type fuses, shall be mounted local
to the instrument(s).
The set of HBC-type fuses is not required for assemblies used as sub-distribution
systems as defined in (Part 1; 1.1).
Add new clause:
7.6.1.3
Switches (mechanical)
Switches shall be of the independent manual operating, air-break type with quick snap
action make and break features.
They shall comply with and be type tested to IEC 60947-3. They shall have a utilization
category AC 22 when switching mixed resistive and inductive loads, and AC 23 when
switching motor loads or other highly inductive loads. The type of loads shall be indicated in
the ‘Schedule for LV Switchboards’.
Switches shall be easily accessible and operable from the front of the switchboard without
opening a cover.
Switching devices shall be of the 4-pole type for 3 phase + neutral systems and 2-pole for
single phase circuits.
The neutral pole of a switching device in balanced 3 phase + neutral systems shall have a
current rating equal to that of the other poles up to and including 63 A and, if above 63 A,
not less than 50 % of that of the other poles with a minimum of 63 A.
Switches shall have a rated (conditional) short-circuit making capacity in conformity with the
prospective short-circuit currents, as specified for the busbar system.
NOTES:
1. The term ‘conditional’ is specified in IEC 60947-1:2004, Clause 4.3.6.4, and covers the current
limiting action of fuses or other protective devices.
2. Incoming and busbar section switches of multi-section boards may have a short circuit rating
based on the actual distribution of the short circuit current. (e.g. 50 % of the maximum short circuit
current flows through each incomer in a coupled two-section board).
DEP 33.67.01.31-Gen.
November 2006
Page 18
All switches used for isolating a circuit shall be padlockable in the ‘OFF’ position. Unless
otherwise stated in the requisition, the padlock facility shall accept hasps of 5 mm as a
minimum.
Add new clause:
7.6.1.4
Circuit breakers
Circuit breakers in outgoing circuits shall only be used if specified in the requisition or with
the approval of the Principal. They shall comply with the requirements as specified for
switches as far as operating accessibility, padlocking and phase and neutral switching are
concerned.
Circuit breakers shall comply with and be type tested to IEC 60947-2 and shall have
utilisation category A or B, however, circuit breakers feeding sub-distribution switchboards
which shall have utilisation category B circuit breakers shall have a rated short-circuit
making and breaking capacity (Ics) in conformity with the prospective short-circuit current as
specified in the requisition.
In exceptional cases and if the prospective short-circuit current is higher than 50 kA, the
selection may be based on Icu. In this case details of the coordination and selectivity, as
well as the consequences of a possible replacement after the circuit breaker is called upon
to operate, shall be discussed and agreed with the Principal.
The ratio between the rated service short-circuit breaking capacity (Ics) and the rated
ultimate short-circuit breaking capacity (Icu) shall be minimum 50 %.
The minimum Ics shall be 10 kA unless otherwise agreed by the Principal.
Circuit breakers in a change-over supply duty should be withdrawable but shall at least
have isolating facilities for maintenance and testing purposes.
NOTE:
Circuit breakers may require a separate DC supply for tripping and/or closing. The Principal shall
advise the details of such DC supply.
Add new clause:
7.6.1.5
Fuses
High breaking capacity (HBC) type general purpose fuse links, utilisation category gG in
accordance with IEC 60269-1 shall be used. The breaking capacity shall be equal to the
short circuit rating of the busbar system with a minimum of 80 kA. The requisition shall
indicate what type of fuse system in accordance with IEC 60269-2-1 shall be installed, i.e.
-
type NH fuse-links with blade contacts (‘DIN’ fuses)
fuse-links for bolted connections (‘BS’ fuses)
Metal removal tags of ‘DIN’ fuses shall be potential free.
‘DIN’ fuses of the D-type shall only be applied up to maximum 63 A and shall be backed up
by short-circuit current limiting devices of maximum 400 A rating to reduce the short-circuit
level.
Add new clause:
7.6.1.6
Motor starters and contactors
As a standard, contactors shall be of the holding coil type with an operating voltage derived
from phase and neutral. If a latched contactor is required for a special purpose, this shall be
indicated in the requisition.
With reference to IEC 60947-4-1, motor starters and contactors shall conform to the
requirements of both uninterrupted duty and intermittent duty class 12 (12 operating cycles
per hour), at rated operational current. They shall have a mechanical durability level of one
million no-load operating cycles.
DEP 33.67.01.31-Gen.
November 2006
Page 19
The utilization category AC-3 (starting of squirrel-cage motors, switching off motors during
running) shall be applied. For motors in inching or reversing rotating service, utilization
category AC-4 shall be used. The Schedule for LV switchboards attached to the requisition
shall indicate to which motors this is applicable.
For special loads such as transformers, capacitors, lighting, etc. a suitable current rating
and utilization category shall be selected by the Manufacturer.
Proper coordination between the contactor breaking capacity and the motor protection, e.g.
earthfault protection (7.6.1.8) shall be ensured.
On-off position indication of contactors shall be provided on the front of the compartment by
clear red light for ‘ON’ and clear green light for ‘OFF’. The indication lights shall be of the
long life, low power consumption type, e.g. LED. Local contactor closing facilities shall not
be provided on the assembly for motor starter units. In addition to the required number of
auxiliary contacts needed for the control and indication circuits, each contactor and motor
starter shall be provided with at least one make and one break contact element, double
gap, potential free, and wired up to the auxiliary terminal block of the compartment.
Reference is made to drawing S 67.004.
Add new clause:
7.6.1.7
Motor overload protection relays
Overload protection relays shall be installed in all phases and shall include protection
against single phasing (at least 10% faster) and shall be at least of trip class 20 in
accordance with IEC 60947-4-1. The relays shall be of the temperature compensated type
and shall be equipped with manually reset facilities on the front of the compartment
(resettable without opening the assembly). An inadvertent reset action shall not trip a
circuit.
If bimetallic thermal relays are used, direct heating elements shall be provided up to a
nominal current of 40 A. For nominal currents above 125 A, standard nominal 5 A or 1 A
relays shall be used in combination with linear current transformers. Between nominal
currents of 40 A and 125 A either direct heating elements or 5 A or 1 A elements connected
via dedicated current transformers may be used.
For motors with running up times in excess of 5 s, saturable current transformers in
combination with a standard nominal 5 A or 1 A relay shall be provided. Alternatively
electronic protection relays with suitable protection curve shall be supplied.
For motors with operating conditions beyond those covered by overload relays, special
protection systems may be considered, e.g. installation of thermistor temperature sensors
in the motor windings with their relays installed in the switchgear compartment. Agreement
shall be reached with the Principal in the quotation stage.
Overload relays protecting electric motors of the Ex’e’ type installed in Zone 1 areas shall
have a current/time characteristic below the maximum locked rotor time (tE) as indicated on
the ‘Schedule for LV Switchboard’ and shall be certified by a ‘Notified Body’ (previously
called Authorised Certification Body).
Add new clause:
7.6.1.8
Motor earth fault protection
Motors of 30 kW and above shall be fitted with core balance type earth fault protection
relays. Relays shall be manually resettable after opening of the compartment cover. The
sensitivity of the relays shall not exceed 3 % of the rated nominal motor current or 6 A,
whichever is the greater. The relays shall be equipped with a clear trip indication on the
relay.
DEP 33.67.01.31-Gen.
November 2006
Page 20
Add new clause:
7.6.1.9
Motor restarting facilities
If specified in the requisition an automatic restart facility shall be provided to restart the
motor after voltage dips of a duration up to typically 4 s. This facility shall be incorporated in
motor starters as indicated in the ‘Schedule for LV switchboard’, and shall be fully
configurable per drive.
The automatic restart facility shall be initiated under the following conditions:
•
•
•
•
Voltage dip detection level at 65 % of Un.
Voltage restoration detection level at 90 % of Un.
Immediate restart after voltage dips ≤ 0.2 s.
Delayed restart after voltage dips of > 0.2 s with an adjustable maximum of 60 s in
steps of 5 s after which the unit shall be not restarted without an external start
command.
• If a second voltage dip, with a duration less than 0.2 s, occurs within 1 s after the first
voltage dip, a delayed restart command shall be given.
• The undervoltage memory time buffer shall be at least 4.5 s.
The minimum detection time for a voltage dip shall be less than the drop time of the
contactor (considered to be 10 ms) therefore ensuring that a voltage dip is detected even
after a transient interruption has occurred.
It shall be possible to set the maximum dip duration, after which the system will initiate a
restart, between 4 s and 30 s.
NOTE :
This longer time may be required if the motor is reconnected to an emergency supply after a power
failure in the normal supply.
If specified in the requisition, each motor control compartment shall be equipped and wired
with a U-type relay base of the ‘Sprecher und Schuh’ type, for future insertion of a restart
relay.
Restart relays shall be included only for those motors as indicated on the schedule
attached to the requisition. Reference is made to drawing S 67.004.
The Manufacturer may offer in his quotation a system without specific use of RR and TRM
modules. The functional requirements for such system shall be as described above.
Specific approval of the Principal shall be required, based on documented evidence that the
specified functionality can be achieved and on type test reports made available in the
quotation stage.
Add new clause:
7.6.1.10 Current transformers
Current transformers (CTs) shall be in accordance with IEC 60044-1.
CTs for measuring purposes shall be of accuracy class 3.
CTs shall include an instrument security factor such that the instruments are not
endangered at maximum fault current.
The secondary current rating shall be 1 A except for dedicated CTs for thermal overload
relays, which may have a 5 A rating (7.6.1.7).
Where applicable, characteristics of CTs for protection and measuring supplies to and from
third parties shall be advised by the Principal. The equipment may be supplied to the
Manufacturer by the Supply Authority.
Protective current transformers shall be of accuracy class 5P unless class 10P is specified
as adequate by the relay Manufacturer. The short-circuit rating shall be at least 1 s if
applied for short-circuit protection. The wiring of the secondary circuits shall have a cross
section of at least 2.5 mm2.
DEP 33.67.01.31-Gen.
November 2006
Page 21
Secondary circuits of all CTs shall be earthed.
NOTE:
1) CTs for motor overload relays shall be as specified by the relay Manufacturer (7.6.1.7).
2) Secondary circuits of CTs integrated in motor overload protection with no exposed secondary
terminals do not require to be earthed.
Add new clause:
7.6.1.11 Voltage transformers
If voltage transformers (VTs) for protection and metering are required, they shall be in
accordance with IEC 60044-2 and shall be of accuracy class 3.
NOTE:
1) VTs are normally not required in LV assemblies with voltages up to 400 V, but may be required for
assemblies with a higher voltage rating, e.g. 660 V.
2) For control voltages the Manufacturer may select VTs to a different specification, subject to
approval by the Principal.
Where applicable, characteristics of VTs for protection and measuring supplies to and from
third parties shall be advised by the Principal. The equipment may be supplied to the
Manufacturer by the Supply Authority.
Unless otherwise specified, the secondary voltage of metering transformers shall be 110 V.
Secondary circuits of VTs shall be earthed.
Add new clause:
7.6.1.12 Measuring instruments
All instruments shall be of the flush mounting type and shall have an enclosure with a
degree of protection of at least IP 41 for indoor and IP 55 for outdoor applications.
All meters should be of the square pattern type, and mounted at a suitable height (7.6.2.1)
for easy reading from the front. Scales shall be graduated in actual values.
As an alternative, the Principal may specify a multi-functional digital measuring device
instead of analogue metering. This shall be specified on the requisition.
Meters shall be installed in the associated functional units. Recording instruments, if
required, may be mounted in any other accessible location or common panel provided that
the equipment is properly labelled.
Ammeters and voltmeters shall be accuracy class 1.5. Watt-hour meters and maximum
demand meters shall be accuracy class 2.5. Requirements for meters for measuring
supplies to and from third parties shall be advised by the Principal. The equipment may be
supplied to the Manufacturer. See IEC 60051 and IEC 62052-11.
Ammeters for motor duty (if required) shall have a compressed overload scale and shall be
suitable to withstand the motor starting currents.
Watt-hour and maximum demand meters shall have cyclometric type registers. All
watt-hour integrating meters shall be fitted with a pulse transmitter for input to a remote
supervisory system or a metering summation scheme.
The number of elements shall be suitable for the system to be measured. Watt-hour meters
in motor circuits, if specified, may be of the single element, balanced load type.
Outgoing feeders to sub-switchboards with current ratings of 400 A and above shall be
provided with an ammeter.
Motor starter units with a motor feeder cable of 4 mm² cross section or larger (usually for
4 kW and above) shall be equipped with a current transformer for a remote ammeter.
Motors connected with a feeder cable of 2.5 mm² shall use a direct reading remote
ammeter.
DEP 33.67.01.31-Gen.
November 2006
Page 22
For assemblies without IMCS, a 4-20 mA output transducer complying with IEC 60688 shall
be provided for each analogue signal to a remote supervisory system (e.g. DCS). The
output signal of the transducer shall be limited to maximum 20 mA, even when the input
value is more than 100 % of the rating (e.g. during motor starting). Detailed requirements
shall be specified in the requisition.
Add new clause:
7.6.1.13 Integrated motor control
Only if specified in the requisition, an Integrated Motor Control System (IMCS) in
accordance with Appendix 1 shall be included in the switchboard. The details and the
extent of the IMCS shall be agreed with the Principal in the quotation stage.
7.6.2.1
Accessibility
Add to this clause:
Replacement of components shall be possible without de-energising a section of the
assembly.
NOTE:
This is not applicable to components directly connected to the main or distribution busbars, e.g. fuse
holders.
A free space of at least 0.2 m shall be available between the lowest cable termination,
switch, push button, indication light or measuring apparatus of a floor mounted assembly
and the floor.
The maximum height of the above-mentioned components shall not be more than 2 m
above floor level.
7.6.2.5
Cooling
Add to this clause:
For switchgear and control assemblies, only natural cooling shall be applied.
7.6.4
Removable parts and withdrawable parts
Add to this clause:
Withdrawable units which are mechanically identical but electrically have a different
function shall be non-interchangeable, e.g. it shall not be possible to install a motor starter
unit into a space for a plain feeder unit of the same size.
DEP 33.67.01.31-Gen.
November 2006
Page 23
7.7
INTERNAL SEPARATION OF ASSEMBLIES
Add to this clause:
Partitions or barriers shall be provided in the assemblies to obtain Form 4(a or b) or 3b
separation of compartments. Form 3b is only acceptable if all terminals have a degree of
protection of at least IP 3X.
The partition shall comply with following degree of protection:
Location
between horizontal busbar compartments and any other
compartment
between incoming and sectionaliser units
between main busbar systems of two separate sections
between panels
between compartment of each functional unit towards other
compartments
NOTES:
Minimum degree
of protection
IP 4X
IP 4X
IP 4X
IP 4X
IP 3XD
Busbar compartments of a section do not need to have partitions between the individual panels.
In multi-box type assemblies used in sub-distribution service as defined in
(Part 1; 1.1), the busbars, incoming feeder and sectionaliser units shall be installed
in separate boxes.
Partitions between the busbar compartments and functional units shall have a
degree of protection of at least IP 2X.
Outgoing circuits up to and including 25 A may be housed in combined boxes
provided the live parts inside the boxes have a degree of protection of at least IP 2X.
The terminals for outgoing cabling shall be clearly identified and termination of the
individual circuits shall be possible without removing the IP 2X protection. Outgoing
cabling shall not pass internally through other functional units. If necessary,
pre-wired terminal boxes shall be provided with a degree of protection inside the box
of at least IP 2X. Cubicle type assemblies used in sub-distribution service as defined
in (Part 1; 1.1) do not require separation of functional units by barriers or partitions
provided the live parts inside the cubicle have a degree of protection of at least
IP 2X.
Operational activities such as switching, replacing fuses, resetting relays, and
termination of outgoing cabling shall be possible without removing the IP 2X
protection.
7.10
ELECTROMAGNETIC COMPATIBILITY
7.10.1
General
Add to this clause:
The LV switchgear and controlgear assemblies shall be suitable for operation in
Environment A.
7.10.3
Immunity
Add to this clause:
EMC immunity for all protection and control functions of all types of assemblies shall be
tested to performance criterion A (Table H5).
NOTE:
Performance criterion A means no noticeable changes, operating as intended.
DEP 33.67.01.31-Gen.
November 2006
Page 24
7.10.4
Emission
Add to this clause:
All assemblies, whether or not incorporating electronic circuits, shall be suitable for
environment A (7.10.1).
DEP 33.67.01.31-Gen.
November 2006
Page 25
8.
TEST SPECIFICATIONS
8.1
CLASSIFICATION OF TESTS
If special tests in addition to the type and routine tests are required, this shall be indicated
in the requisition.
NOTE:
8.2
An example of a special test would be vibration tests for assemblies to be installed on e.g. offshore
structures (6.2).
TYPE TESTS
Add to this clause:
Type tests shall be carried out in accordance with IEC 60439-1 provided that additional
requirements specified (e.g. busbar insulation, diversity factor, etc.) are taken into
consideration.
With regard to internal arc testing, assemblies shall be tested to confirm the successful
assessment of the Criteria 1 to 5 of IEC TR 61641.
NOTE:
These test are categorised as ‘special tests’.
Certificates shall be available at the quotation stage. Certificates issued by independent
testing laboratories are preferred.
Components installed within the assembly shall be type tested in accordance with the
applicable IEC publications (e.g. IEC 60947). Certificates, obtained from the Manufacturers
of the components, shall be made available at the request of the Principal.
DEP 33.67.01.31-Gen.
November 2006
Page 26
8.3
ROUTINE TESTS
Add to this clause:
Before dispatch the Manufacturer shall carry out the full routine tests in accordance with
IEC 60439-1 on the total assembly, or parts thereof if delivered separately, and the results
shall be recorded in a test report.
If specified in the requisition, the Principal shall witness the final routine testing, for which
the Principal shall be given at least ten working days’ notice.
The witnessed final factory inspection and tests shall be carried out on the complete
assembled switchgear. Transportable units can be wired together instead of being joined at
the busbars. Test reports of routine tests already carried out shall be available.
During the witnessed inspection and test the following checks and tests shall at least be
carried out:
-
Review of test reports of routine tests already carried out.
Switchgear shall be visually inspected for technical execution and conformity with the
latest issue of the approved drawings and with the order. Spot checks shall be made to
verify:
• degree of protection of the enclosure;
• degree of protection within the compartments;
• effectiveness and reliability of safety shutters, partitions and shrouds;
• effectiveness and reliability of operating mechanisms, locks and interlock systems;
• insulation of the busbar system;
• creepage distances and clearances;
• proper mounting of components;
• internal wiring and cabling system;
• correct wiring of main and auxiliary circuits;
• suitability of clamping, earthing and terminating arrangements;
• correct labelling of functional units;
• completeness of the data on the nameplate;
• availability of the earthing system throughout the switchgear;
• interchangeability of electrically identical components;
• non-interchangeability of mechanically identical but electrically different withdrawable
units (7.6.4).
-
An insulation resistance test shall be performed between each phase and neutral
against earth, with the remaining phases and neutral connected to earth. The insulation
resistance tests shall be carried out with all manually operated and latched type
switching devices in the closed position and all main fuses installed. The insulation
resistance measured shall be at least 5 MΩ. The voltage applied shall be at least
1.1 times Un d.c.
-
A dielectric test shall be carried out in accordance IEC 60439-1, but for 1 min.
-
The mechanical and electrical operation of a number of functional units, including their
control and protective devices, shall be tested on a random basis. Unless otherwise
specified in the requisition, these tests shall be done on 10 % of the number of similar
functional units with a minimum of two units.
The IMCS shall be fully tested in accordance with Appendix 1 (A1.8)
DEP 33.67.01.31-Gen.
November 2006
Page 27
PART 3 REFERENCES
In this DEP, reference is made to the following publications:
NOTE:
1. Unless specifically designated by date, the latest edition of each publication shall be used,
together with any amendments/supplements/revisions thereto.
2. The DEPs and most referenced external standards are available to Shell staff on the SWW (Shell
Wide Web) at http://sww05.europe.shell.com/standards/.
SHELL STANDARDS
Standard Form: Schedule for LV switchboard
DEP 33.67.01.80-Gen.
Requisition for LV switchboard
DEP 33.67.01.93-Gen.
Requisition for lighting distribution board
DEP 33.67.01.94-Gen.
Requisition for engineering documents ("RED" form)
DEP 40.10.01.93-Gen.
Spare parts
DEP 70.10.90.11-Gen.
STANDARD DRAWINGS
Schematic diagrams of control circuits for LV motors
S 67.004
LV switchboard panel identification
S 67.021
Switchgear, electrical instruments and diagrams
S 67.xxx
INTERNATIONAL STANDARDS
Instrument transformers – Part 1:
Current transformers
IEC 60044-1
Instrument transformers – Part 2:
Inductive voltage transformers
IEC 60044-2
Direct acting indicating analogue electrical-measuring
instruments and their accessories
IEC 60051
Electrical apparatus for explosive gas atmospheres
Part 10: Classification of hazardous areas
IEC 60079-10
Method for the determination of the proof and
comparative tracking indices of solid insulating
material
IEC 60112
Low-voltage fuses – Part 1: General requirements
IEC 60269-1
Low-voltage fuses – Part 2-1: Supplementary
requirements for fuses for use by authorizes persons
(fuses mainly for industrial application) – Sections I to
V: Examples of types of standardized fuses
IEC 60269-2-1
Low-voltage switchgear and controlgear assemblies –
Part 1: Type-tested and partially type-tested
assemblies
IEC 60439-1
(1999 + A1:2004)
Degrees of protection provided by enclosures
(IP code)
IEC 60529
Insulation coordination for equipment within
low-voltage systems – Part 1: Principles, requirements
and tests
IEC 60664-1
Electrical measuring transducers for converting a.c.
electrical quantities to analogue or digital signals
IEC 60688
DEP 33.67.01.31-Gen.
November 2006
Page 28
Low-voltage switchgear and controlgear - Part 1:
General rules
IEC 60947-1:2004
Low-voltage switchgear and controlgear – Part 2:
Circuit-breakers
IEC 60947-2
Low-voltage switchgear and controlgear – Part 3:
Switches, disconnectors, switch-disconnectors, and
fuse-combination units
IEC 60947-3
Low-voltage switchgear and controlgear – Part 4-1:
Contactors and motor-starters – Electromechnical
contactors and motor-starters
IEC 60947-4-1
Enclosed low voltage switchgear and controlgear
assemblies - Guide for testing under conditions of
arcing due to internal fault
IEC TR 61641
Mobile and fixed offshore units –
Electrical installations, Part 3: Equipment
IEC 61892-3: 1999
Electricity metering equipment (AC) General
requirements, tests and test conditions Part 11:
Metering equipment
IEC 62052-11
Issued by :
Central Office of IEC (Sales Dept)
3 Rue de Varembé
1211 Geneva 20
Switzerland
Copies can also be obtained from national standards organizations.
DEP 33.67.01.31-Gen.
November 2006
Page 29
APPENDIX 1
A1.1
INTEGRATED MOTOR CONTROL SYSTEM (IMCS)
INTRODUCTION
This Appendix specifies the technical requirements for a microprocessor based Integrated
Motor Control System (IMCS) incorporated into an LV Switchgear Assembly to control,
protect and monitor both motors and feeders.
General requirements as stated in the main body of this DEP (and IEC 60439-1 on which
the DEP is based) apply to the IMCS unless otherwise specified in this Appendix.
The requisition shall state whether the Manufacturer of the Assembly shall offer an IMCS
system, or whether a conventional system is required, in which case this Appendix is not
applicable.
The Manufacturer may be requested to offer both alternatives in which case the
Manufacturer shall include in his quotation an economic evaluation of both options.
When IMCS is specified, the requisition shall state the detailed requirements for its
functionality.
IMCS designed by the various Manufacturers differ from each other in terms of hardware,
software and communication protocols. The Manufacturer should give appropriate details in
his quotation and confirm that the functionality as requested in this Appendix and the
requisition for IMCS is met.
As a guidance a simplified block diagram of the IMCS is given in Figure A1.1.
A1.2
DEFINITIONS AND NOMENCLATURE
Definitions stated in (1.3) shall apply.
A1.2.1
SPECIFIC DEFINITIONS
In addition to the Definitions in (1.3.2):
Motor Control Unit
(MCU)
A microprocessor based device with integrated control, monitoring
and protection functions and communication facility serving a single
motor starter.
Feeder Control Unit
(FCU)
A microprocessor based device with integrated control, monitoring
and protection functions and communication facility serving a single
contactor, circuit breaker or fused feeder.
Central Control Unit
(CCU)
A microprocessor based interface device used to monitor and
control a number of MCUs and FCUs via a serial bus and enabling
communication with a higher level of control.
Integrated Motor
Control System
(IMCS)
A system comprising control modules, central unit(s), a serial bus
connecting the control modules to the central unit and a
communication facility enabling connection of the central unit to a
distributed control system (DCS) and/or a Supervisory Control and
Data Acquisition System (SCADA).
Engineering Work
Station (EWS)
Interface device for the management of the IMCS parameters and
read out of data.
Hand Held Terminal
(HHT)
Portable interface device that can be plugged into individual
control units to read out data and manage selected parameters of
the control units.
NOTE:
The term Control Units covers MCUs, FCUs, CCUs and combined configurations thereof.
DEP 33.67.01.31-Gen.
November 2006
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A1.2.2
ABBREVIATIONS
DCS
IPF
SCADA
- Distributed Control System - control system of the (process) plant.
- Instrumented Protective Function (Safeguarding)
- Supervisory Control and Data Acquisition System
A1.3
GENERAL
A1.3.1
SCOPE OF SUPPLY
The scope of supply of the IMCS shall include:
•
Detailed design
•
Supply of materials
•
Supply of software
•
Installation of the system within the switchgear assemblies
•
Factory inspection and testing
•
Documentation
And where specified in the requisition or order:
A1.3.2
•
Spare parts
•
Site installation
•
Commissioning (incl. site inspection and testing) and start-up assistance
•
Simulation unit to be used as training tool (A1.5.12)
RESPONSIBILITY
The ultimate responsibility for the system including the software package(s) required to
operate the IMCS shall be with the Manufacturer of the LV Switchgear and Controlgear
Assembly. The type, make and extent of the IMCS shall be agreed with the Principal at the
quotation stage.
The Manufacturer of the LV Switchgear and Controlgear Assembly shall be responsible for
the performance of the IMCS as described in this specification and shall liaise with the
Manufacturer of the DCS and/or SCADA for procedures, execution of interface and testing.
The Principal shall advise the make, type and other applicable details of the DCS and/or
SCADA. The Manufacturer of the IMCS shall be responsible for obtaining certified field test
reports for the communication with these systems using the actual IMCS configuration to be
supplied.
A1.3.3
INFORMATION TO BE SUBMITTED WITH THE QUOTATION
The Manufacturer shall submit a technical specification of the IMCS, which shall include a
description of the design, operation, construction, performance and maintenance aspects of
the equipment.
The Manufacturer shall confirm in the quotation that the equipment fully complies with this
specification and the applicable international and national standards and directives. Where
applicable the Manufacturer shall supply type test certificates to verify such compliance.
Any deviations from this specification shall be highlighted and the technical consequences
of these deviations shall be given in detail.
NOTE:
All IMCS systems for installation in countries within the European Union (EU) Trading Area shall be
supplied with the required CE certificate and markings in accordance with local legislation. In addition
the entire installation shall conform fully to all the applicable EU Directives.
DEP 33.67.01.31-Gen.
November 2006
Page 31
The Manufacturer shall state in the quotation the country of origin of the main components
of the system. For maintenance and trouble shooting at site, the Manufacturer shall indicate
the nearest service organisation recommended for the location where the equipment will be
installed.
A1.3.4
LIFETIME CONSIDERATIONS
The assemblies shall have a design lifetime of at least 25 years, under the service
conditions specified and maintained according to the Manufacturer's recommendation
(7.1.1).
The lifetime of the IMCS may not satisfy the above requirement. The Manufacturer of the
Assembly shall clarify and confirm in the quotation:
• the realistic lifetime expectancy of the IMCS and its individual components, e.g. EWS
and HHT;
• that during the lifetime of the assemblies, replacement Control Units and spare parts
shall be available;
• that during the lifetime of the assemblies, support for the applied software shall be
available;
• that any new generation of this equipment including software developed subsequent
to delivery shall have the same functionality as that of the original equipment, and it
shall be relatively easy to extend, modify or adapt the original equipment or software
to incorporate such new developments;
• that these replacements can physically be fitted in place of the original equipment
and that replacement can be realised without de-energising a section of the
Assembly.
A1.3.5
RELIABILITY
A1.3.5.1 The design of the IMCS shall be such that the MTTR (Mean Time To Repair) shall be
minimised. This means that suitable plug-in modules are preferred over conventionally
wired ones. The Manufacturer shall also provide estimated MTTR figures for all
components with the tender.
A1.3.5.2 Failure rate including all component failures shall be less than 0.50 % over the lifetime of
the units. The MTBF (Mean Time Between Failure) of the MCU/FCU and CCU modules
shall not be less than 150,000 h.
A1.3.5.3 The hardware of the IMCS shall be suitable for the service conditions as specified for the
switchgear assembly in (6). To prevent failures due to the temperature rise in the assembly,
all electronic components shall be derated and all the PCBs shall be subject to a suitable
burn-in.
A1.3.6
SPARE PARTS
The Manufacturer shall include in his quotation sufficient spare parts to fully cover the
on-site commissioning activities. In addition the Manufacturer may be requested in the
requisition to provide a detailed quotation for spares covering 2 years of operation (see
DEP 70.10.90.11-Gen.).
DEP 33.67.01.31-Gen.
November 2006
Page 32
A1.4
BASIC REQUIREMENTS
A1.4.1
CONFIGURATION
The IMCS shall be a microprocessor based motor/feeder protection, control and monitoring
system generally comprising:
•
MCUs and FCUs mounted in or adjacent to the Functional Units (starter or feeder
compartments) of the Assembly.
•
A CCU arrangement per Substation linking the MCUs and FCUs, in that substation.
•
The CCU(s) shall be able to be connected to at least one EWS.
•
The CCU arrangement shall provide separate serial connections to the plant DCS
and SCADA systems via a serial link or an Ethernet connection.
•
EWS(s) and HHT(s) or a combination of these two, generally a laptop PC.
•
Current transformers and if required voltage transformers and transducers for
protection, measurement and control.
•
All software required for the operation of the IMCS as specified.
The Manufacturer shall in principle offer his standard design that provides the functionality
as described in this Appendix. The IMCS offered may not fully follow the description of the
various components indicated above.
NOTE:
1. As an example, IMCS may be designed without the CCU. Communication from the MCU/FCU to
the process and maintenance systems could be direct via e.g. ‘Profibus’, with gateways installed
where necessary.
2. Figure A1.1 gives a typical block diagram incorporating the components stated above. The
Manufacturer’s standard may differ from this.
A1.4.2
REDUNDANCY
The requisition shall state whether redundancy in the connection between the MCU/FCU
and the CCU is required. If this is the case, one failure in the connection shall not cause an
interruption in the communication to any of the MCU/FCUs.
Where 100 % system availability of the IMCS is required a dual redundant CCU and a dual
redundant serial link configuration shall be provided. This shall be indicated in the
requisition.
If a dual redundant CCU arrangement is required it should be a ‘Master – Slave’ hot
standby system, such that in the event of a failure of one unit, the second shall take over
control in a bumpless fashion and shall also provide both a local and remote alarm to
indicate the failed unit. The Manufacturer may propose a different back-up arrangement,
subject to approval by the Principal. The system shall be designed so that any failure in any
part of the system shall not result in loss of availability of the system.
A1.4.3
SERVICE CONDITIONS
The service conditions are as specified in the main body of the DEP (6), where applicable
as modified in the requisition.
The IMCS shall be capable of withstanding and maintaining operation during and after the
supply voltage and frequency deviations specified in IEC 60439-1 clause 4, as amended in
the main body of this DEP (4).
DEP 33.67.01.31-Gen.
November 2006
Page 33
A1.5
TECHNICAL REQUIREMENTS
A1.5.1
GENERAL
A1.5.1.1 Motor circuits and where applicable outgoing feeders shall be controlled by the MCU or
FCU which performs measurement, control and protection and constitutes a complete and
self sufficient system with a non-volatile memory of all specific pre-programmed
parameters.
A1.5.1.2 The use of battery back up for MCU and FCU is not permitted. The Control Units shall be
able to automatically maintain operation capability after a voltage interruption.
A1.5.1.3 The Control Units shall be adequately protected against external short circuits or earth
faults on the connected control cables and shall maintain full operation after clearance of
any such fault.
A1.5.1.4 In the event of a failure of the protection and control functions of an individual MCU/FCU,
the associated circuit shall be field configurable to either automatically trip or to maintain
the current operation.
In the event of a communication failure of any individual MCU/FCU or any failure of the
CCU the associated circuit(s) shall be field configurable to either trip or maintain the current
operation. Any such failure of either the communication or the MCU/FCU shall generate an
alarm in the CCU for onward transmission to the DCS.
The default configuration to be adopted for all MCU/FCUs shall be as agreed with the
Principal.
A1.5.1.5 All protection and control devices shall incorporate self-supervision and checking routines
with watchdog function to indicate all system errors and/or failures directly to the CCU
and/or EWS for onward transmission to the DCS.
A1.5.1.6 Programming of the protection and operational parameters shall be carried out via an EWS
or via a local keypad on the MCU/FCU. Once protection and operating parameters are
loaded into the system, they shall be stored in non-volatile memory so that all information is
retained during power failures. The need to reload parameters from an EWS or HHT
following any power failure is not acceptable.
A1.5.1.7 In the event of a failure of an individual MCU/FCU module it shall be possible to replace
any failed module and readily download or program the specific drive/feeder parameters to
the replacement module via an EWS or HHT without specialised software knowledge. The
specific drive/feeder parameters shall be stored in the memory of the EWS.
A1.5.1.8 The EWS shall be able to set the parameters and to monitor the operating status of any
connected drive or feeder.
A1.5.1.9 Access to change the operating parameters shall be restricted by means of a password or
key.
A1.5.1.10 Monitoring of the operating status of all connected drives and or feeders, including a log of
alarms, shall be available via the Principal’s SCADA and/or maintenance management
system as applicable.
A1.5.1.11 The IMCS shall be capable of displaying the following either directly from MCU/FCU or at
the CCU or EWS.
•
•
•
•
•
•
Alarm outputs including watchdog alarms.
Pre-trip conditions.
Stop control of motors.
Motor/Feeder status - Available/Running/Tripped etc.
Trip LED Indication plus type of trip.
Running/Stop LED indication.
DEP 33.67.01.31-Gen.
November 2006
Page 34
A1.5.2
MOTOR CONTROL, PROTECTION AND MEASUREMENT
Reference is made to Table 1, Matrix of typical IMCS features.
A1.5.2.1
All motor starter units, whether of the direct-on-line or dual speed type etc., shall be
equipped with an MCU. The MCU shall constitute of a self-sufficient monitoring, control
and protection system. Each device shall provide as a minimum the following
functionality:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Status (running stopped, tripped).
Number of contactor operations.
Motor current.
Motor running up time (time from start to reaching operational speed).
Motor operating time (operating hours).
Motor overload protection, setting, status, pre-alarm and time to trip. The unit
shall model the hot and cold motor thermal capacity utilising fixed or adjustable
thermal time constants. Certified thermal curves for Ex’e’ motors shall be
incorporated, see (7.6.1.7).
Load unbalance protection, setting and status, including pre-alarm.
Thermal status of the motor, including restart inhibit time.
Earth fault protection for motors over 30 kW, setting and status, see (7.6.1.8).
Stalling protection setting and status.
Local Stop.
Reset of alarms and trips via a password or key for locked rotor and earthfault.
Manual reset of all other alarms and trips.
Configurable inputs for external trips (2 as a minimum).
The following functionality shall be provided if specified on the Requisition:
•
•
•
•
•
Automatic re-start on loss of voltage, as defined in (A1.5.3).
Monitoring of consumed active power and the power factor.
Thermistor or Pt100 element for over-temperature protection including pre-alarm.
Under-current protection, setting and status, including pre-alarm.
Under-voltage trip for latched contactors, setting and status, per unit or from a
central unit.
A1.5.2.2
The control set-up of the MCU shall allow for possible additional hardwired control of the
motor.
A1.5.2.3
The Manufacturer may, in addition to the earthfault protection scheme as mentioned in
(A1.5.2.1), propose an alternative scheme if this forms part of their standard IMCS
system. Specific approval by the Principal shall be required.
A1.5.2.4
MCUs may provide either a 4-20 mA or 0-20 mA output for connection to the Remote
Control Unit (RCU) ammeter as an alternative to a dedicated 1A secondary current
transformer (7.6.1.10).
A1.5.2.5
Trending and recording facilities shall be made available for monitoring and recording by
the EWS and the Principal’s SCADA and/or maintenance management system on an
as-required basis. A facility for generating printouts of events and trend logs from the
EWS by connecting a standard printer shall be incorporated.
It shall be possible to configure all measurable variables such as current, power etc. for
trend recording and to define the recording trigger event such as a motor start.
DEP 33.67.01.31-Gen.
November 2006
Page 35
A1.5.2.6
Unless specified differently by the Principal, every drive shall be controlled as detailed
below:
-
Local, adjacent to the motor
Local control shall be from a position close to the motor. This is done via at least one
Remote Control Unit (RCU) and/or Safety Switch (SS) allowing the motors to be
started and stopped manually. The RCU is a three position switch with "Off-0-On"
positions, spring return to the "0" position allowing remote automatic control by the
DCS. For contactor controlled motor starters the "Off" position of the RCU/SS can be
padlocked and shall be regarded as a safety switch. In this position the RCU/SS
shall be hardwired into the motor starter contactor circuit. Furthermore an additional
contact of the RCU/SS shall be used to short circuit the contactor coil when the RCU
is in the "Off" position.
All RCU/SS stop commands shall in all cases overrule the IMCS. The RCU/SS shall
at all times be able to stop the drive even with the MCU defective.
All control schemes shall be in line with the existing standard RCU/SS arrangement
as shown on Standard Drawing S 67.004.
-
Remote, from a DCS/IPF system
Remote control shall be possible from the DCS or IPF system. This type of control, if
required for plant operation, shall be applied in addition to the manual control
described above. Automatic process control shall consist of the following:
•
"On" and "Off" controls.
•
IPF control signals, which shall be hardwired into the motor starter circuit.
•
DCS control signals, which may be hardwired into the motor starter circuit or
preferably serially connected into the IMCS, as determined by the Principal.
No “On” command may be given by the MCU, EWS or HHT during normal plant
operating conditions.
A1.5.3
AUTOMATIC RESTART OF MOTORS
If specified in the requisition an automatic restart facility shall be provided within the IMCS
to restart the motors after voltage dips of a duration up to typically 4 s. If specified, this
facility shall be incorporated in all MCUs, and shall be fully configurable per drive.
The functional requirements shall be as specified in the main body of this DEP (7.6.1.9).
A1.5.4
FEEDER CONTROL, PROTECTION AND MEASUREMENT
The requisition shall state for which feeders, if any, FCUs are required.
Feeders that are equipped with an FCU shall provide as a minimum the following:
•
•
Switching device status.
Feeder current.
The following functionality shall be provided if specified on the Requisition:
•
•
•
•
•
Consumed active power.
Power factor.
Overcurrent protection (adjustable for co-ordination purposes).
Earth fault protection (With adjustable tripping time for co-ordination purposes).
Reset of earth fault alarm and trip via a password or a key.
DEP 33.67.01.31-Gen.
November 2006
Page 36
A1.5.6
COMMUNICATIONS
A1.5.6.1 Each MCU and FCU shall have a serial connection for communication with the higher-level
control and monitoring units. The required redundancy shall be given in the requisition
(A1.4.2). The CCU and/or EWS shall be able to communicate with all the MCUs and FCUs
in the Switchgear Assemblies within a single Substation.
Each MCU and FCU shall be selectable from the EWS and/or HHT via a unique equipment
tag number as defined by the Principal in the Schedule for LV switchboard (form
DEP 33.67.01.80-Gen). Selection by module address only is not acceptable.
A1.5.6.2 The IMCS shall communicate with the DCS via either a single or dual redundant serial link,
as stated in the requisition (A1.4.2). This communication shall interface directly to the DCS
control network. If a communication interface module is not available for the selected DCS
Manufacturer, the communication to DCS shall be via a serial link (DCS master, IMCS
slave). A TCP/IP connection may be used if approved by the Principal.
A1.5.6.3 In case of loss of communication with the DCS or SCADA system, the IMCS shall continue
to operate undisturbed unless configured otherwise.
A1.5.6.4 The serial data link from the Substation to both the DCS and/or SCADA systems shall be
either a single or a fully redundant link by either a twisted pair copper cable or preferably a
fibre optic cable. The Manufacturer shall indicate the preferred cabling arrangement for the
selected protocol in the quotation.
A1.5.6.5 The Manufacturer shall provide certified field type test reports verifying the successful
communication of the CCU with the selected DCS and/or SCADA system. The
Manufacturer shall ensure that the IMCS can communicate effectively with the selected
higher-level system and shall supply the required converters and software. The
Manufacturer and the nominated DCS/SCADA Manufacturer shall provide a field simulation
demonstration of the communication link between the two systems using all the required
converters and software.
A1.5.7
RESPONSE TIME
A1.5.7.1 The set up of the IMCS shall be such that ‘stop’ commands from the DCS system shall
always have priority over data collection and other DCS commands.
A1.5.7.2 The SCADA and maintenance management systems are primarily data collection and
monitoring systems. The preferred method of data collection is for the CCU data to be
loaded into a table, which is then refreshed at regular intervals, and the SCADA system
only accesses data on request.
A1.5.7.3 The Manufacturer of the IMCS shall specify the response and scan times of the system for
control and monitoring. The maximum response time for priority control/data signals shall
not be greater than 0.6 s with the maximum number of MCU/FCU modules connected to
the system.
NOTE:
A1.5.8
The response time is measured from receipt of the command from the DCS at the IMCS, to the
confirmation that the command has been actioned.
CURRENT AND VOLTAGE TRANSFORMERS
A1.5.8.1 Current transformers shall be in accordance with (7.6.1.10)
DEP 33.67.01.31-Gen.
November 2006
Page 37
A1.5.8.2 Voltage transformers, if required, shall be in accordance with (7.6.1.11).
NOTE:
The application of voltage and/or current sensors other than traditional CTs and VTs shall only be
permitted after specific approval by the Principal.
A1.5.8.3 The earth fault protection current transformer of the motor circuits shall be of the core
balance type with the accuracy to maintain the sensitivity specified in (7.6.1.8).
A1.5.9
CONTROL SUPPLY
A1.5.9.1 The Manufacturer shall give in his quotation full details of the voltage requirements for the
different devices of the IMCS. This shall include estimated load figures for these devices.
A1.5.9.2 The Manufacturer shall provide all converters required for the control, monitoring, indication
etc. of the IMCS.
A1.5.9.3 The power supply to the individual MCU and FCU modules shall be as specified on the
requisition and either be derived from its related starter/feeder unit or from a centralised
power supply. If no preference is stated on the requisition, the Manufacturer shall quote his
preferred method.
The control of the motor from the RCU shall be as specified in (A1.5.2.6), i.e. control
voltage shall be phase-neutral derived from the individual starter.
A1.5.9.4 Where a centralised DC power supply is required a DC/DC converter shall be included in
the CCU power supply unit to avoid the CCU earthing an external DC power source such
as the substation trip/close DC supply.
A1.5.10 THE MOUNTING OF MCU AND FCU MODULES
A1.5.10.1 MCU and FCU modules shall be suitable for mounting in the motor starter/feeder
compartments or in an adjacent (common) compartment. If the unit is mounted within the
starter unit, the electronics shall be rated accordingly (A1.3.5.3). The degree of protection
(IP), as defined in (7.7), shall not be undermined by any ventilation requirements.
A1.5.10.2 The interface between the installed starter/feeder unit and the communication bus within
the Assembly shall be an integral part of the starter/feeder. The starter/feeder compartment
shall remain withdrawable and the connection to the communication bus shall be a single
connection using self-centring plugs and sockets.
A1.5.11 TEST FACILITIES
Facilities shall be provided to allow functional testing of the MCU and FCU modules,
without having to run the motor.
This facility may be provided by a test setting on the switchgear, an umbilical cord for the
controls to allow testing outside the assembly or by means of a stand alone test rig to
simulate all possible control functions, including the automatic restart function if applicable.
A1.5.12 TRAINING FACILITIES
If specified in the requisition a simulation unit to be used as a training tool shall be provided.
This unit shall be complete with all the required software, converters and cabling to enable
maintenance and operation staff to become fully conversant with the routine operation and
maintenance of the MCU, FCU and CCU. This unit may be used in collaboration with the
DCS Manufacturer for communication field testing.
DEP 33.67.01.31-Gen.
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Page 38
A1.5.13 ENGINEERING ACCESS
A1.5.13.1 The IMCS software shall allow access for engineering purposes to any MCU or FCU, on
or off line. Facilities shall be provided to change setpoints, prepare or examine a motor
trend analysis, etc. Access to vital motor settings and the CCU/EWS configuration shall
be governed by a password.
A1.5.13.2 Three levels of access shall be available on the EWS and/or HHT:
Level 1 :
View Only
The engineer or operator shall only be able to view the set parameters and actual
data but is not permitted to change any settings or reset any lock out trips.
Level 2 :
Settings and Reset
The engineer shall be able to reset all trips and reconfigure the MCU and FCU
control and protection parameters.
Level 3 :
Configuration
It shall be possible to reconfigure the system to accommodate additions and
modifications to the system and configure the CCU/DCS/SCADA communication
parameters.
A1.5.14 SOFTWARE
All software shall be menu-driven, and all configurations of the communication to the
DCS/SCADA and the loading and modification of drive/feeder setpoints shall be designed
for use by engineer/technicians without specialised software knowledge.
Connection to EWS and HHT via USB port is preferred
The Manufacturer shall provide a demonstration version of the applicable software for
training purposes.
A1.6
ELECTROMAGNETIC COMPATIBILITY (EMC)
Reference is made to IEC 60439 1, clause 7.10, as supplemented in the main body of this
DEP (7.10.1, 7.10.3 and 7.10.4).
A1.6.1
COMMUNICATION INTEGRITY
The communication interface bus between the CCU and the MCU/FCU shall be tolerant to
electromagnetic disturbances and shall be fully protected against any short circuit or similar
faults without loss of communication.
Failure of the communication bus shall generate an alarm to the Central Control Room via
the CCU but the current state of devices shall be maintained unless configured otherwise.
A1.6.2
ELECTRICAL IMMUNITY
The IMCS shall be able to withstand the impact of the electrical tests imposed upon the
Assembly as defined in (8), without any damage to or malfunction of the IMCS.
Loss of control power supply shall not result in the loss of the application software, data or
the dynamic data relevant to the operation of protection systems, e.g. available thermal
capacity of motors (up to 60 s) and operation of the automatic motor restart. On restoration
of the power supply the system shall be able to automatically resume normal operation.
Battery back-up of individual MCU and FCU modules is not acceptable.
DEP 33.67.01.31-Gen.
November 2006
Page 39
A1.7
CONSTRUCTIONAL REQUIREMENTS
A1.7.1
UNIT ENCLOSURE
A dedicated compartment or panel shall be provided when the CCU and/or the EWS is built
into the switchgear assembly. With respect to the degree of protection (IP as defined in
IEC 60529) of the devices mounted in the switchgear assembly, the requirements stated in
(7.2), (7.4) and (7.7) apply.
The CCU enclosure, if mounted separately, shall have a degree of protection not less than
IP 41. The floor shall not be considered as forming part of the enclosure.
For EWSs, standard PCs are preferred; HHTs should be commercially available laptop
PCs. The Manufacturer shall give details in his quotation.
A1.8
INSPECTION AND TESTS
A1.8.1
GENERAL
Prior to dispatch of the Switchgear Assemblies including the IMCS, the Manufacturer shall
verify by tests that the operation of the equipment complies with the requirements specified
in the requisition, and shall submit to the Principal a report incorporating the results of all
tests performed.
At the quotation stage the IMCS Manufacturer shall submit a test protocol and programme,
regarding inspection and testing of the components and total IMCS. This programme shall
include a 24 h heat-soak and burn in of the components.
If specified on the requisition, a representative of the Principal shall witness the functional
factory acceptance tests (A1.8.3 & A1.8.4) and shall carry out an inspection of the
assembled equipment and related documents to verify compliance with the requirements of
the purchase order. The extent and further details of the witnessed testing shall be agreed
at the quotation stage.
A1.8.2
TYPE TESTS
The Manufacturer shall submit to the Principal, for review and approval, the type test results
of the electrical, disturbance and environmental immunity test requirements as defined
in (A1.6).
A1.8.3
TESTING THE COMMUNICATION OF THE IMCS AND THE DCS
A full functional communication test with the DCS shall be included in the test programme.
The test shall verify all aspects of the communication between the DCS and the IMCS. All
functions of the IMCS shall be tested and verified.
A1.8.4
TESTING OF THE IMCS IN THE LV SWITCHGEAR ASSEMBLY.
Each of the MCU and FCU modules shall be functionally tested. Additionally the operation
of the CCU, EWS and the communication between all MCU and FCU and higher level
systems shall be verified.
As far as practicable, the IMCS shall be programmed with the actual protection and control
parameters as provided by the Principal.
DEP 33.67.01.31-Gen.
November 2006
Page 40
In the LV switchgear works the Switchgear Assembly including the IMCS shall be subject to
a full routine test that shall include, but shall not be limited to the following:
•
•
•
•
•
•
•
•
NOTE:
A1.9
Test as specified in IEC 60439-1, as supplemented in the main body of the DEP (8).
Verification of protection functions and settings (overload, earthfault, etc.).
Verification of measurement functions (current, power etc.).
Verification of input and output functions (status, external control, alarms etc.).
Verification of the continuous operation after a power interruption.
Verification of the external hardwired commands (e.g. IPF, SS, etc.).
Verification of the automatic restart function (if specified).
Thermistor/Pt 100 input tests (if specified).
Protection functions shall be tested by means of primary injection, thus proving the proper operation
under fault condition from primary input to alarm and trip functions.
INSTRUCTIONS FOR INSTALLATION, OPERATION AND MAINTENANCE
In addition to the drawings/documents mentioned in (5.3), the following shall be supplied:
•
General arrangement drawings showing MCU/FCU dimensions, CCU dimensions,
EWS dimensions, HHT dimensions, mounting details of the units, connections etc.
•
Cabling and wiring diagrams showing power input, output, terminals of MCU/FCU,
CCU, HHT, EWS interface connections.
•
Setpoint setting tables for all MCUs and FCUs as set in the factory, as hardcopy and
on computer media.
•
Configuration software on computer media for CCU and MCU/FCU.
•
Programming (logic) diagrams.
•
Certificate of conformity for communication with DCS/SCADA systems.
DEP 33.67.01.31-Gen.
November 2006
Page 41
C O N TR O L & M O N ITO R IN G
FIGURE A1.1 Simplified block diagram of IMCS
PR O C ESS
IPF
SU BSTATIO N
M aintenance
M anagem ent
System
DCS
G atew ay
Interposing
R elay Box
FIELD
EN G INEER IN G
C CU
SC AD A
EW S
LV Switchgear
M CU
FC U
M
A
Feeder
RCU
= Connection ofhandheld term inal
DEP 33.67.01.31-Gen.
November 2006
Page 42
Table A1.1
Matrix of typical IMCS features
This table indicates:
• What information can be seen (gathered) at the location
• What action can be taken at location
• What protection features are included
i
i (l)
a
*)
: indication
: indication by LED
: action
: feature may also be available at compartment
Feature
Status
motor running
motor stopped
motor tripped
MCU healthy
Operation
start of motor (In addition to RCU)
stop of motor (in addition to RCU/SS or IPF)
automatic restart (optional)
Number of contactor operations (on – off)
Operating hours
Motor current
Active power and power factor (optional)
Overload protection
setting
status
pre-alarm / time to trip
thermal status of motor
restart inhibit time
reset (manual)
history of trips, etc.
Unbalance protection
setting
status
reset (manual)
history of trips, etc.
Location
Compartment
On switchgear or in Substation (CCU and/or EWS)
DCS
i (l)
i (l)
i (l)
i
i
i
i
i
i
i
i
Maintenance
Management
System
a
a
a
a
i *)
i *)
i *)
i *)
a
i *)
i *)
i *)
i *)
a *)
i
a
i *)
a *)
i
i
i
i
i
i
i
i
i
DEP 33.67.01.31-Gen.
November 2006
Page 43
Feature
Location
Compartment
Stalling protection
Earth fault protection (motors > 30 kW)
Thermistor protection (optional)
(or Pt 100)
Under current protection (optional)
setting
status
reset (key/password)
history of trips, etc.
setting
status
reset (key/passwordl)
history of trips, etc.
setting
status
pre-alarm / time to trip
thermal status of motor
restart inhibit time
reset (manual)
history of trips, etc.
setting
status
reset (key/password)
history of trips, etc.
On switchgear or in Substation (CCU and/or EWS)
a
i *)
a *)
i
a
i *)
a *)
i
a
i *)
i *)
i *)
i *)
a *)
i
a
i *)
a *)
i
DCS
Maintenance
Management
System
i
i
i
i
i
i
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