015-PH-1911 R1 Variable Speed Drive Controller

(d. p. &) ctcl4yl " u zrfi KUWAIT OIL COMPANY (K.S.C.)

Engineering Group

Specification Number 0 75-pH- 19 1 I

Variable Speed Drive Con troller

1 17 JUN 94 ISSUED AS KOC ENG GROUP SPEC

0 7 MAR 93 ISSUED FOR INVITATION TO BID

Rev Date Revision BY Chkd Section PE Client

Specification Number Rev Date Sheet Engineering Group Spedtkation O I ~ - P H - I ~ I I I 17-6-94 2 of 20

CONTENTS

1 1.0 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2.0 STANDARD SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3.0 SERVICE CONDITIONS 5 1 4.0 BASIC ENGINEERING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

5.0 CONSTRUCTION REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

6.0 PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

7.0 VARIABLE SPEED DRIVE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . 9

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 EARTHING 11

9.0 WIRING AND TERMINALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

10.0 CABLE TERMINATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

. . . . . . . . . . . . . . . . . . . 11.0 CONTROL AND PROTECTION EQUIPMENT 13

12.0 ELECTRONIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

13.0 ANTI-CONDENSATION HEATERS . . . . . . . . . . . . . . . . . . . . . . . . . 18

14.0 NAMEPLATES AND LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

15.0 PAINTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

16.0 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1 General 19

. . . . . . . . . . . . . . . . . . . . . . . 16.2 Electronic Component Tests 19 16.3 Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 16.4 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 16.5 Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 16.6 Motor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 16.7 String Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

17.0 PACKING. MARKING AND DOCUMENTATION . . . . . . . . . . . . . . . . 20

18.0 SPARE PARTS AND MAINTENANCE REQUIREMENTS . . . . . . . . . . . 20

1.0 SCOPE

1 .I This specification covers the design, manufacture, inspection, testing and supply of variable speed drive controllers for installation at the Facility in Kuwait.

1.2 The variable speed drive controllers shall fully comply with all relevant contractual requirements specified in the Scope of Work and Technical Specification of the Contract.

2.0 STANDARD SPECIFICATIONS

2.1 The variable speed drive controllers shall conform in design, materials and performance, except where otherwise specified, with the current issue and amendments of the following prevailing on the effective date of the Contract:

2.1 .I International Standards

IEC 51

IEC 70

IEC 76

IEC 146

IEC 185

IEC 186

IEC 255

IEC 269

IEC 282

IEC 439

IEC 664

IEC 947

Recommendations for Direct-Acting Indicating Analogue Measuring Instruments and Their Accessories

Power Capacitors

Power Transformers

Semiconductor Convertors

Current Transformers

Voltage Transformers

Electrical Relays

Low-Voltage Fuse

High-Voltage Fuses

Low-Voltage Switchgear and Controlgear Assemblies

Insulation Co-ordination Within Low-Voltage Systems Including Clearances and Creepage Distances for Equipment

Low-Voltage Switchgear and Controlgear

2.1.2 British Standards

Engineering Group Specification

BS 800 Limits and Methods of Measurement of Radio Interference Characteristics

2.1.3 Other Standards

Specification Number

01 5-PH-1911

Engineering Recommendation G5/3 - Limit for Harmonics in the United Kingdom Electricity Supply System (Electricity Council, Sept 1976).

2.1.4 Engineering Group Specifications

Rev

1

The variable speed drive controllers shall conform to all relevant Engineering Group specifications of which the following are specifically referred to in this specification:

01 5-AH-1001 Basic Design Criteria

Date

17-6-94

01 5-AH-1 002 International Codes and Standards

Sheet

4 of 20

01 5-KH-1902 Spare Parts and Maintenance Requirements

01 5-NH-1104 PlantIEquipment Noise Control

01 5-PH-1902 High-Voltage Switchgear

01 5-PH-1903 Power Transformers

01 5-PH-1905 Low-Voltage Switchgear and Motor Control Centres

01 5-PH-1908 Induction Motors

01 5-UH-1001 Packing, Marking and Documentation

01 5-XH-1005 Shop and Field Painting

2.2 Compliance with this specification shall not relieve the Contractor of its responsibility to supply equipment suited to meet the specified service conditions and applicable regulations.

2.3 Where conflicts exist between this specification and other Drawings, standards, codes and specifications, the most stringent shall be applied.

2.4 Equipment may comply with other National Standards subject to receipt of prior written approval from Company.

Specification Number Rev Date Sheet Engineering Group Specification 01 5-PH-1911 1 17-6-94 5 of 20

3.0 SERVICE CONDITIONS

The equipment shall be suitable for continuous operation at a desert location under high ambient temperatures and humidity. The atmosphere at the Facility is generally dusty and corrosive and may contain traces of hydrogen sulphide.

The variable speed drive controller units shall be new and in all respects suitable for continuous operation in the service conditions stated in the Engineering Group Specification entitled "Basic Design Criteria" (Number 01 5- AH-1001).

The minimum degree of protection for enclosures in accordance with IEC 947 shall be as follows:

3.3.1 Indoor equipment assemblies: IP4X.

3.3.2 Outdoor equipment assemblies: IP55.

Reliability of all equipment to perform continuously in the service conditions specified is essential. Equipment typical of that being supplied shall have been in operational use elsewhere for a minimum of two years. Prototype or unproven equipment not having a well-established record shall not be considered.

All equipment, including contactors, transformers, fuses, relays, all other current-carrying parts, all auxiliary devices, etc. shall have the specified ratings, which shall be their continuous rating as installed in the equipment after being suitably derated for the specified service conditions.

The variable speed drive controller shall be designed to provide a minimum mean time between failure (MTBF) of 30,000 hours. The variable speed drive controller shall be designed to provide a mean time to repair (MTTR), with service personnel on-site, not exceeding 4 hours.

4.0 BASIC ENGINEERING INFORMATION

4.1 The variable speed drive controller shall be suitable in all respects for operation on a 3-phase, 50-Hz supply.

4.2 The variable speed drive controller shall be suitable for continuous operation, without deleterious effect, with variations of supply voltage and frequency as follows:

4.2.1 Voltage * 6%.

4.2.2 Frequency k 2.5%.

Variable speed drives rated at 120 kW or less may be connected to the 440-V supply. For drives of greater than 120 kW, each variable speed drive controller shall be fed from a high-voltage system unit transformer, unless otherwise specified on the single-line diagram.

The unit transformer and oil-cooled reactors or inductors shall comply generally with the Engineering Group Specification entitled "Power Transformers" (Number 01 5-PH-1903) and shall be suitable for operation with non-sinusoidal current wave shapes and DC components under normal and abnormal conditions of the variable speed drive system without exceeding the specified maximum operating temperature. Additional windings shall be included as necessary for the design requirements.

Motors shall be 3-phase, squirrel-cage induction motors and shall comply generally with the Engineering Group Specification entitled "Induction Motors" (Number 01 5-PH-1908) and shall be suitable for use with the variable speed drive system without exceeding the maximum design temperature. Motors for use in hazardous areas shall be certified for use within the area classification applicable as specified in the above Engineering Group specification and shall be certified for use in conjunction with the particular variable speed controller from which it is supplied.

Electrical components for incorporation into the variable speed drive controller shall comply with the relevant IEC standards. These shall be selected to exclude readily combustible insulating and constructional material and excessive heat generation. Electrical and mechanical reliability is of the utmost importance. The components shall have been type tested to the relevant IEC standard.

5.0 CONSTRUCTION REQUIREMENTS

5.1 The variable speed drive controller shall be housed in a free-standing, floor- mounting, dust - and vermin-proof, metal-enclosed enclosure permitting front access only. It shall be complete with all necessary instruments, controls, indicators, connections, circuit breakers, isolators, fuses and ventilation. The rectifier and inverter equipment shall be assembled together. The bypass facility components shall be located in a separate compartment.

5.2 The equipment shall be designed to minimise risk of an internal short circuit. It shall also provide for personnel and operating safety during all operating conditions, inspections and maintenance. Under extreme conditions of major short circuits or mal-operation, there shall be no danger to persons in the vicinity of the equipment. Interlocks and covers shall be provided to prevent incorrect or unsafe operation and to prevent access to live parts.

5.3 The enclosure shall be constructed from folded and welded mild sheet steel not less than 2 mm thick.

Specification Number Rev Date Sheet Group , specification 015-PH-1911 1 17-6-94 7 of 20

Cable entry shall be via 3-mm thick removable gland plate(s). Gland plate(s) shall be of adequate size to accommodate the cables required.

Front access door(s) shall be sufficiently rigid and close fitting to exclude dust. Gaskets of neoprene or other approved material shall be used to provide a seal. Hinged doors shall not exceed 900 mm wide and shall be fastened by means of a T-type key lockable handle. Doors shall have facilities to restrain them in the open position.

Door-mounted equipment shall be arranged in a logical manner for ease of operation, inspection and maintenance.

All live terminals and door-mounted equipment shall be shrouded or otherwise protected by barriers providing a degree of protection IP2X with the enclosure door(s) open. This shall apply to all doors or frames giving access to internal components.

The enclosure and equipment within shall be cooled in order of preference by natural air cooling, forced air cooling or water cooling. It is not expected that water cooling would be used for controllers rated below 2000 kW. Redundancy shall be provided in the forced cooling system such that any one cooling fan, pump or heat exchanger failing on any thyristor stack shall not impair the unit performance. Particular attention shall be paid to the location of ventilation louvres and their arrangement. Dust filters shall be provided on all louvres and shall be easily replaceable during operation.

Controller noise level shall not exceed 65dB(A) measured 1 m from the equipment, at any position and at any load between zero and 100%. Reference shall be made to the Engineering Group Specification entitled "Plant/Equipment Noise Control" (Number 01 5-NH-1104).

5.10 The enclosure design shall allow work to be carried out safely on the variable speed drive controller, when isolated, without contact with live parts, with the motor operating on fixed speed bypass.

6.0 PERFORMANCE

6.1 The variable speed drive system shall comprise:

6.1.1 Transformer/incoming supply.

6.1.2 Controller.

6.1.3 Motor.

6.1.4 Driven plant.

Q KM: Engineering Group Spew'fication 6.2 The system shall be designed as a coherent whole to give the required

performance characteristics. The characteristics shall be suited to those of the driven equipment with due regard to the operating and transient conditions, including torsional analysis and critical speed avoidance.

I I

-

6.3 The variable speed drive controller shall be capable of withstanding the thermal and dynamic stresses and the transient mechanical torques such as those resulting from a short circuit. Any damage resulting from such a short circuit or internal fault shall be confined to the component concerned.

Specification Number

01 5-PH-1911

6.4 The variable speed control system shall be designed so that in the event of a component(s) failure or power supply loss, the system shall fail in a safe condition.

N12-0110

Date

17-6-94

Rev

1

6.5 The controller shall be fault tolerant so that no single processor or component failure causes shutdown.

Sheet

8 of 20

6.6 The variable speed drive controller shall comprise the following major components arranged in a modular construction:

Disconnection device.

Rectifier.

DC Link.

Inverter.

Commutation circuits.

Filter.

Controller bypass circuit including motor starter.

Controls and display panel.

6.7 The motor starter shall be either direct on-line, reduced-voltage Korndorfer type or static soft-start as required to meet the specified voltage dip limitations.

6.8 For motors of 120 kW or less rating (440 V), the variable speed drive controller shall be of a 6-pulse configuration, with a torque characteristic to match the requirements of the driven equipment. The controller for drives larger than 120 kW shall be of a 12- or 24-pulse configuration, depending on the design and size of the drive. The configuration shall be selected to meet the specified limitations on harmonic currents and voltages.

Specification Number Rev Date Sheet Engineering Group Spewfication 015-PH-1911 1 17-6-94 9 of 20

6.9 The variable speed drive controller shall be rated for 100% full-load current, duty class II in accordance with IEC 146, and meet all torque requirements for the supply voltage and frequency variation stated herein.

Acceleration and de-acceleration times shall be independently programmable as a minimum for 1 to 250 seconds.

The variable speed drive controller shall incorporate inherent voltage dip protection. The protection shall ensure continuous operation for voltage transients down to 70% system voltage for a duration less than or equal to 3 seconds. For voltage transients greater than the criteria stated, the variable speed controller shall be locked out.

The set frequency of the drive shall be maintained within rt 1 % irrespective of variation in load. Speed regulation shall be uniform and bump free.

Normal rated speed shall be 5% less than the maximum speed. The speed control shall be calibrated for a range of 0 % to 105%.

The harmonic currents and voltages introduced to the electrical system at all voltage levels shall not exceed the limits of Engineering Recommendation G513, either individually or in total, for the Facility. Any necessary calculations and measurements shall be performed by the Contractor.

Provision shall be made for future addition of harmonic reduction equipment as it is anticipated that similar equipment shall be installed at other facilities.

The radio frequency interference from the equipment shall not exceed the limits specified in BS 800.

The equipment performance shall not be affected by externally produced electromagnetic fields.

7.0 VARIABLE SPEED DRIVE CONTROLLER

7.1 The variable speed drive controller shall provide the following speed control modes:

7.1.1 lnput for auto speed control in the form of a 4 - 20mA signal, powered from the Distributed Control System (DCS) 24-VDC power supply.

7.1.2 lnput for remote manual speed control in the form of raise and lower pushbuttons.

7.1.3 In-panel speed control for maintenance and commissioning purposes only. This control shall be so arranged so that access is limited to authorized personnel only.

7.2 The variable speed drive controller shall be microprocessor controlled providing on-line monitoring and self-diagnostics. The following minimum controls shall be provided:

7.2.1 Onloff control switch.

7.2.2 Emergency stay-put stop pushbutton.

7.2.3 Programmable control unit incorporating keypad and alpha-numeric LCD display. The display shall include:

a. Operating parameters with set points and actual values.

b. Selection of parameters from programmes for adjustment and monitoring.

c. Faults, alarms and diagnostic messages.

I 7.2.4 Startlstop inverter. 7.2.5 Electrical bypass transfer switch.

7.3 The minimum following programmable set points shall be provided:

7.3.1 Maximum and minimum speeds.

7.3.2 Calibration of 4 to 20mA input signal.

7.3.3 Maximum and minimum torque settings.

7.3.4 Motor ramp times.

7.3.5 Controller current limit.

7.4 Thyristor banks shall be provided with redundancy so that a failure of one or two thyristors shall not cause system failure. Thyristors shall be monitored such that any failure shall initiate an alarm.

7.5 110-VAC control supplies for variable speed drive controllers shall be derived internally within the controllers from transformers.

7.6 Where the variable speed drive system is subject to automatic control, it shall be designed so that start signals are only acknowledged following initial operation of a pushbutton, soft-key or sequence initiate. Under no circumstances shall the drive start on reset of a stop switch or trip device.

Where sequence interlocks and control functions are carried out via electronic control systems, safety interlocks, especially those for personnel protection, shall be designed to act directly into the main power supply disconnection device feeding the controller. The disconnection device shall be an integral part of the controller. lntertrip signals in the form of two volt-free change- over contacts from the controller shall be provided.

An emergency stop stay-put pushbutton shall be provided on the controller and local to the motor. These pushbuttons shall be hard wired, configured in series with the controller Emergency Shutdown (ESD) input and defined as a safety interlock in accordance with the preceding clause.

Volt-free auxiliary contacts shall be provided to interface with the DCS and indicate Drive Stopped, Drive Running and Drive Available.

7.10 Variable speed drive systems shall include a testlnormal selection facility operable from the controller by a key switch. When test is selected, the controller shall be controlled from the in-panel speed control. When normal is selected, the controller shall be controlled from either the control station local to the motor or via the 4-20mA input (selectable by a local/off/remote facility on the local control station). All stop pushbuttons shall operate regardless of switch positions.

Control facilities local to the motor shall be combined in a common control station incorporating local/off/remote selector switch, startlstop pushbuttons, raisellower speed pushbuttons, emergency stay-put stop pushbutton, speed indication and current indication. When located in a hazardous area the control station shall be certified for hazardous area use.

7.12 Essential interlocks and safety trip devices shall remain operable in all circuit configurations.

8.0 EARTHING

8.1 An earth bar shall be provided along the full length of each enclosure. All metallic non-current-carrying parts shall be bonded together and connected to the earth bar. External M I 0 earthing terminals shall be provided to facilitate connection of the enclosures to the earthing system.

8.2 Panel-mounted equipment with exposed metal parts such as indicating lights, pushbuttons, and relays shall be separately earthed.

8.3 Provision shall be made for connecting the earth continuity conductors and cable armoring of all outgoing circuits.

Specification Number - eng~neering Group

01 5-PH-19' a I Y LID? I Shen n .I nrr I 8.4 Doors and hinged parts shall be bonded to the switchgear structure by means

of a flexible copper connection having a minimum cross-sectional area of 6 mm2 arranged so that it cannot be trapped as the door is opened or closed.

8.5 Connections from the main earth bar to components shall consist of copper strips or greenlyellow PVC-sheathed stranded copper conductors. Termination lugs shall be of the compression type.

9.0 WIRING AND TERMINALS

9.1 The internal wiring shall be carried out in a minimum of 1.5 mm2 stranded copper conductor 60011 000-V grade PVC-insulated wires. A minimum of 2.5 mm2 shall be used for current transformer wiring; solid conductors shall not be used. Wiring shall be configured so that its insulation shall not be subject to injurious temperature.

9.2 Internal wiring shall be adequately supported by clamping of loomed runs or installed in plastic trunking. Self-adhesive fixings are not acceptable. The supporting arrangements for wiring shall be such that they are not liable to cause permanent physical damage or deformation to the conductor or insulation. Wiring shall not be bent to a radius less than the permissible value given by the Approved Manufacturers. Trunking fill shall not exceed 75% of its capacity.

9.3 Internal panel wiring shall be identified by proprietary heat-shrinkable ferrules at each end, with numbers allocated by the Contractor. All wiring Drawings produced by the Contractor shall clearly identify the appropriate reference numbers. All wiring shall be terminated with pin-crimped terminations.

9.4 Terminal blocks shall be arranged to facilitate accessibility for cable-core termination and inspection of terminal identification numbers. Terminals shall be of the pinch-plate type, Klippon manufacture or Company-approved equivalent, suitable for a minimum conductor size of 1.5 mm2.

9.5 Terminal blocks shall be logically grouped, indelibly marked and provided with removable plastic shrouds. Segregation of different voltage level within terminal blocks shall be achieved by barriers. Voltage levels shall be clearly identified by labels.

9.6 No more than one wire shall be inserted into any one terminal. Looping between terminals, when required, shall be carried out using the purpose- made top of block cross connection or comb-type busbar.

9.7 Terminal blocks associated with external sources of supply shall be fully shrouded and fitted with a danger warning label.

9.8 Terminals associated with external current monitoring signal shall be provided with, easily removable shorting plugs.

9.9 At least 300-mm clearance shall be allowed between the gland plate and any internal equipment to permit easy cable installation and connection.

Back of panel wiring shall be so arranged that access to the connecting stems of relays and other apparatus and to contacts of control and other switches is not impeded.

9.1 1 Wiring looms crossing from fixed to hinged panels shall be mechanically supported on both panels, adjacent to the hinged side, by means of saddles or compression-type supports.

9.12 Wiring colours shall comply with the following:

I Neutral Conductor I Black I 440-VAC Phases

I G h i n a Conductor I GreenNellow I

Red, Yellow, Blue

AC Control Wiring I Black

I

I DC Supply Positive Red or with Red I Markers DC Control Wiring

9.13 Spare terminals equal to at least 25% of the total used shall be provided to enable any spare multicore cable conductors to be terminated.

Grey

I I 0 * O CABLE TERMINATIONS 10.1 Undrilled removable gland plates shall be provided on cable

termination compartments.

10.2 All cable entries shall be from bottom and, all connections will be made from the front of the panel.

10.3 The terminals shall be so arranged that dressing and connecting of cables can be done safely, and without exposure to adjacent live functional units.

10.4 Inside the compartments separate terminals or bolts of adequate dimensions, one for each cable, shall be fitted for cable armoring earthing purposes.

I 11-O CONTROL AND PROTECTION EQUIPMENT 11.1 The variable speed drive controller shall be fully protected to prevent

damage to the motor or to any internal components.

In by-pass operation the motor circuit protection specified below shall be provided. This shall take the form of electronic/static motor protection relays and shall be provide the following as a minimum:

Short circuit.

Overload. This protection shall include a motor thermal image with memory.

Locked rotor.

Unbalanced loading (negative sequence and current).

Motor winding temperature.

Motor earth fault.

Extended motor starting time.

Undervoltage release (time delayed). Controllers, transformers and other equipment shall be provided with the following minimum protection:

Undervoltage, overvoltage, over-frequency and over-fluxing.

DC link earth fault/overcurrent.

Internal components monitored for over-temperature and thyristor failure.

Reactor oil temperature and pressure.

Malfunctioning of control equipment.

Unit transformer earth fault, overcurrent, oil and winding over- temperature and oil level and oil pressure.

Alarm, diagnostic and fault messages shall be displayed on liquid crystal displays. All alarms and fault messages shall have data- logging facilities with battery-backed memory. A serial data link (RS232C) shall be provided for transfer of data to the DCS or a printer.

Where a motor is equipped with resistance temperature detectors and thermocouples, a temperature-monitoring unit shall be provided. It shall be of the flush-fronted, door-mounting type and provide a selectable digital readout for each of the temperature detectors. Alarm and trip contacts shall be provided

Specification Number Rev Date Sheet , . . --- - - 3ring Group

Spm'fication 015-PH-1911 1 17-6-94 15 of 20

in the form of volt-free change-over contacts.

LED brightness shall be such that displays are clearly visible in normal artificial lighting levels.

A lamp test pushbutton shall be incorporated on the front of the cubicle.

All alarm indications shall be latched until reset by means of a reset command.

Analogue-indicating instruments shall be the 72-mm square-flush type and comply with IEC 51, Class 1 and have 240 scale movements. The instruments shall be back connected and have external zero adjustment. The minimum scale reading shall not be less than 20% of the normal or full-load reading. All facias shall be white and pointers black; scale shall be in actual values. A red line or adjustable red pointer to indicate the normal operating point shall be provided.

Digital displays shall be accurate to at least & 1 volt or f 1 amp. Metering and indication shall be corrected to read true rms values of voltage and current.

The variable speed drive controller shall be fully protected to prevent damage to any internal components. All circuits shall be adequately protected by means of circuit breakers or fuses, double pole for DC circuits. The protective devices shall be readily accessible.

The following metering shall be provided on the controller as a minimum:

Motor voltage, current and speed.

Frequency output to motor.

DC link voltage and current.

Hours run.

Provision shall be included for display of the following signals remote from the controller:

Motor speed.

Motor current.

Motor power in kW.

The equipment shall conform with the appropriate requirements of the Engineering Group Specifications entitled "High-Voltage Switchgear" and "Low-Voltage Switchgear and Motor Control Centres" (Numbers 01 5-PH-1902 and 01 5-PH-1905). Each variable speed drive controller shall be provided with a means of isolation for the incoming supply suitable for the voltage and current pertaining. The means of isolation shall be mechanically interlocked with the equipment doors such that access can only be obtained in the isolated position. Onloff indication shall be provided and the operating handle shall be padlockable in the off position.

Sufficient auxiliary contacts shall be provided for isolation of other external voltage sources.

Circuit breakers shall be used instead of isolators and contactors where the contactor and/or fuse ratings available are not sufficient to handle the larger motors.

Contactors shall be 3-pole, self-aligning, double-break, with a current rating suitable for its application at the maximum ambient temperature.

Contactors shall be suitable for both uninterrupted and intermittent class 3 duties, utilization category AC3, and shall be provided with auxiliary contacts as listed below:

To energise the motor anti-condensation heater when the motor is not running or isolated.

Two NO and 2 NC volt-free contacts wired out to terminals via isolator auxiliary contacts.

Semi-conductors shall be protected by high-speed fuses.

Miniature circuit breakers shall be fitted with thermal and magnetic trips according to IEC 947.

Fuses shall be of the HRC type and fitted in fully insulated carriers and bases.

Voltage transformers within the controller shall comply with the following:

Transformers shall be in accordance with IEC 186, double wound with an earth screen between the primary and secondary windings. The transformer rating shall be 120% of worst case burden.

11.23.2 The earth screen shall be brought out to a termination point adjacent to the transformer and connected to the main earth bar within the controller. The primary and secondary windings shall be protected by suitably rated protective devices.

Current transformers shall comply with the requirements of IEC 185. The secondary winding of current transformers shall be earthed at one point through a removable link, with provision for attaching test links. Current transformers shall be rated to withstand the thermal and magnetic stresses resulting from through fault current.

All alarms shall be both visual and audible. Test, accept and reset pushbuttons shall be provided. Alarms shall be provided to assist maintenance personnel in identifying faults down to card level.

Volt-free contacts shall be provided for remote alarm purposes. A contact shall be provided for each individual alarm, and contacts shall be wired to terminals, grouped as applicable to serve as common alarms.

Alarms shall be arranged so that their operation may be checked by simulation, which is as close as possible to the alarm condition.

11.28 Cubicles shall be provided with internal illumination suitable for connection to an external 250-VAC supply.

ELECTRONIC EQUIPMENT

12.1 All connections to sub-assemblies, e.g. transformers, semi-conductor heat- sink assemblies, control modules, etc, shall be made via centralised termination or connection blocks.

12.2 Printed circuit boards shall be replaceable without the use of a soldering iron. (Indirect edge connectors are preferred).

12.3 Useful test points and adjustment points shall be placed such that it is not necessary to reach past exposed live parts during live measurements/testing.

12.4 All exposed live parts shall be shrouded and provided with warning labels. Printed circuit boards shall be tropic proofed.

13.0 ANTI-CONDENSATION HEATERS

Space heaters, controlled by thermostats, shall be provided for each compartment. Heaters with isolating switch fuse and neutral link shall be suitable for 250-V, single-phase supply from an external source. Surface temperature of all heaters shall not exceed 1 60C. Power for motor anti-condensation heaters shall be from the same source. Separate protection shall be provided for each heater sub-circuit.

14.0 NAMEPLATES AND LABELS

Each unit and main sub-assembly shall have a nameplate clearly and indelibly marked with the data specified in the appropriate IEC standard. Nameplates shall be fixed with non-corrodible screws or rivets.

The unit shall have a label on its front at high level showing the unit designation number.

An engraved instruction notice shall be affixed to the equipment in a prominent location. The notice shall list procedures to be employed in switching for startup, shutdown, maintenance and test operations.

Warning labels shall be provided in all locations where necessary to warn personnel of potentially dangerous situations.

All instruments, selector switches, indicators, etc. shall be provided with descriptive labels.

All solid-state or other equipment which can be damaged when subjected to high voltage shall be provided with a warning label stating that they must not be subjected to high-voltage tests.

Labels shall have black characters on a white background, except warning labels shall have white characters on a red background.

All labels shall be engraved on plastic-laminated material and secured with non-corrodible screws; adhesive or self-tapping screws are unacceptable.

All components incorporated within the unit shall be indelibly marked with the component circuit reference. Handwritten stickers or dyno-tape labels are unacceptable.

15.0 PAINTING

Painting shall be in accordance with the Engineering Group Specification entitled "Shop and Field Painting" (Number 01 5-XH-7005).

I 16.0 TESTING Engineering Group Specification

16.1 General

The tests shall be performed at the Approved Manufacturer's Works and shall include those listed below.

Specification Number

01 ~-PH- I~ I 1

1 16.2 Electronic Com~onent Tests 16.2.1 Circuit burn-in at 70C dynamically at 85OC statically for 160

hours. Parametric tests are to be made before and after the burn-in phase.

Rev

1

16.2.2 Memory bit check on EPROMs. After a soak of 1 OOC for 72 hours, repeat memory bit check.

16.2.3 Functional test of microprocessor.

Date

17-6-94

16.3 Printed Circuit Boards

Sheet

19 of 20

16.3.1 In-circuit tests: These tests shall check the correctness of the assembly and verify the soundness of all active and passive components.

16.3.2 Functional tests: To verify the operation of the completely assembled printed circuit boards when energised and exercised over the full operating range.

16.4 Wiring 16.4.1 All edge connector sockets, outgoing terminals, and internal

connecting wiring shall be tested for electrical continuity and correctness of circuit connections.

16.4.2 Insulation testing at the appropriate volta e shall be performed at all possible terminal points. All tests sha 7 I be performed before the insertion of the completed system module assembly. The test shall be a 100% test on all sockets, terminals and connections.

1 6.5 Functional Test

16.5.1 T pe tests shall be carried out in accordance with IEC 146 and 4 !I 9 and shall include the following:

a. The complete assembled controller shall be subjected to a complete functional test when energised to verify its operation. The test shall be performed in conjunction with computerised test equipment providing all required input and output simulated signals.

I c. Harmonic current content of input wave form. I b. Harmonic current content of output wave form.

d. Verification of protective devices.

e. Verification of the properties of the trigger equipment. f. Light load test.

g. Verification of transfer system from controller operation to electrical bypass and vice versa.

h. Load test at rated current.

i. Determination of power losses. j. Measuring of audible noise. k. All units shall be subjected to a full load burn-in for a

duration of 24 hours.

16.5.2 For standard range controllers where type test certificates are available, routine tests in accordance with IEC 146 and 439 shall be performed.

16.6 Motor Tests

Complete tests shall be performed as stated in the Engineering Group Specification entitled "Induction Motors" (Number 01 5-PH-1908).

16.7 Strina Test 16.7.1 All controllers and their associated motors shall be connected

together for performance of the following tests: a. Eight-hour full-load test at maximum speed.

b. Eight-hour full-load test a minimum speed. 16.7.2 The above specified test shall be contiguous with the following

tests performed:

a. Harmonic current content of output wave form.

b. Harmonic current content of input wave form. c. Measurement of power factor.

d. Temperature rise.

e. Measurement of vibration levels.

17.0 PACKING, MARKING AND DOCUMENTATION For all relevant requirements, refer to the Engineering Group Specification entitled "Packing, Marking and Documentation" (Number 01 5-UH-1001).

18.0 SPARE PARTS AND MAINTENANCE REQUIREMENTS For all relevant requirements, refer to the Engineering Grou Specification entitled g "Spare Parts and Maintenance Requirements" (Number 01 -KH-1902).