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• Installation and testing at jobsite (except technical supervision, if required byPurchase Order documents).
• All external equipment, such as power transformers and motors, which arecontrolled and /or protected by the switchgear and motor controller covered in thisspecification.
2.0 CODES AND STANDARD
All equipment and materials furnished will be in compliance with the latest applicablerequirements of the following codes and standards:
ANSI American National Standard InstituteASTM American Society for Testing Materials
IEC International Electrotechnical CommissionIEEE Institute of Electrical and Electronics EngineersNEC National Electrical Code (NFPA _ 70, USA)NEMA National Electrical Manufacturers AssociationNESC National Electrical Safety Code (ANSI C2)UL Underwriters Laboratories, Inc.HSEC Escondida Health, Safety, Environmental and Community StandardSEC Chilean Electrical Standards for “High” and “Low” Currents
Suppliers proposing equipment and materials that are designed, manufactured and
tested to requirements other than those specified above will submit adequatedocumentation to enable BHPB to determine suitability of proposed equipment forintended application.
All equipment, components, materials and services to be furnished under thisspecification will comply with the applicable requirements of Occupational Health andSafety Administration (OSHA).
In the event of conflicts between codes, the most stringent shall apply.
3.0 GENERAL REQUIREMENTSEach Switchgear and Motor Controller assembly will be designed, manufactured andtested according to the latest applicable codes and standards. Where requirements ofthis specification are in conflict with these standards, the specification will takeprecedence.
All equipment, components, materials, engineering and construction will be suitable forthe duty specified and according to reference drawings and data sheets.
All equipment, components and materials furnished will be new, of premium qualityand of essentially heavy-duty design, either meeting or exceeding the requirements of
this specification. The Switchgear and Motor Controller will be not test versions orprototypes.
Specific requirements of each Switchgear and Motor Controller assembly that is to befurnished under this specification (plan, arrangement, ratings, metering, relaying, etc.)will be given on reference drawings and Data Sheets which will be part of the Requestfor Quotation (RFQ) and/or Purchase Order.
Ample space will be provided for incoming supply connections, feeder cables, controlcables and conduits connecting to this equipment.
All equipment and components will be of recent manufacture and design, for whichreplacement parts and service are readily available.
Equipment nameplates will be inscribed with ratings applicable for installation atelevation specified. Nameplates will be in Spanish.
Equipment will be an assembly of standard Medium Voltage Metal-clad Switchgearand Medium Voltage Motor Controllers. Where combinations of equipment typeshaving different standards of construction are included in the same assembly, eachportion will individually meet their own standards. All equipment will be suitable for the
application and will be complete from incoming supply connections to outgoing feeder,control and relaying connections.
Where shipping splits are required, all necessary hardware will be supplied forassembly of equipment. Coordination of both mechanical and electrical connections forthe switchgear assembly will be responsibility of Supplier.
4.0 ELECTRICAL SYSTEMS CHARACTERISTICS
The electrical equipment included shall be designed and constructed for operation on
power systems with the following characteristics:
• Plant Distribution:13.8 kV, 50 Hz, 750 MVA (Ssc, to be confirmed by AMEC), 3 phases, resistancegrounded wye.4.16 kV, 50 Hz, 350 MVA (Ssc, to be confirmed by AMEC), 3 phases, resistancegrounded wye.480 volt, 50 Hz, 65 kA (Isc, to be confirmed by AMEC), 3 phases, 3 wire, solidlygrounded wye.
The enclosures shall be freestanding steel structures with standard hinged doors andwill be provided for future extension at both ends. They will be arranged for entry ofmain service cables and feeder cables as indicated on the reference drawings andData Sheets.
The enclosures shall be suitable for indoor installation.
The enclosures shall have adequate strength to withstand all stresses imposed byseismic actions, shipping, handling and operation, etc, without distortion or other-damage.
Each enclosure will be provided with barriers to segregate high and low voltagesystems.
Each draw-out circuit-interrupting device will be equipped with padlockable groundedmetal automatic safety shutters. That covers the live fixed primary contacts to protectpersonnel when the moving portion is removed.
Each assembly cell will be compartmentalized for main bus, circuit interrupting device,outgoing cables and auxiliary devices, with all inter compartment passages beingsealed.
Enclosures shall have gasketed rear access doors with hand operated door latchesand provisions for padlocking at each vertical section.
5.3 Switchgear bus work
Switchgear bus work will be fabricated from high conductivity copper and will beinsulated. Bus will be rated according to reference drawings and Data Sheets andbraced to withstand short circuit currents in the magnitude specified therein. All bus
joints and connections will be silver plated.
Bus tap connection to each circuit interrupting device will have a continuous currentcarrying capacity of not less than the rating of the equipment served. In case of draw-out devices, the bus tap rating must equal or exceed the maximum rating of any circuitinterrupting device, which can be accommodated.
The Switchgear will be equipped with a rectangular copper ground bus, which willextend through each unit of the structure. The bus will be provided with terminal lugs at
both ends and at each compartment to accommodate # 1/0 AWG to 250-kcmil copperground conductor.
All bus insulation will be of flame-retardant, track-resistant type.
Isolating barriers, as applicable, will be provided between the incoming and the mainbus system to prevent fault communication.
5.4 Circuit Breakers
All main and feeder circuit breakers will be metal-clad 3-pole, vacuum or SF6, draw-out, electrically operated, and stored energy type. Circuit breakers ratings and
operating voltages will be as shown on reference drawings and Data Sheets. Eachcircuit breaker will be complete with closing and tripping mechanisms, auxiliaryswitches, holding coils, relays, mechanical position indicators (closed-open), operationcounters and accessories. In addition, each breaker will be equipped with a manualmaintenance-closing and tripping device.
All circuit breakers of identical voltage and current ratings and their associatedcomponents will be completely interchangeable without requiring any rewiring ormodifications.
One high arrangement will be used for the power circuit breakers and they will be
installed in the lower position of each Switchgear cell.
Stationary and auxiliary contacts in a draw-out breaker will be silver plated type.
Auxiliary and position switches will be provided for basic control functions such as anti-pumping, pilot indication, electrical interlocking, breaker testing and status. In addition,each breaker will be provided with a minimum of 4 normally open and 4 normallyclosed spare auxiliary contacts, which will be wired out to terminal blocks.
Each breaker will be provided with mechanical interlocking to:
• Prevent circuit breaker insertion or removal except when in "Open" position.• Prevent circuit breaker closing at any position between test and operation position.
It will be supplied a padlockable safety handle mechanism to provide the means forlockout in the off position each circuit breaker.
Circuit breakers will have continuous and interrupting current ratings according toreference one line diagrams and Data Sheets.
Incoming section bus will be complete with all the necessary hardware and terminallugs to accept incoming feeder cables as specified on reference drawings and DataSheets.
Power cable terminal lugs will be provided at each feeder breaker, which will acceptcopper cables of the size and quantities shown on reference drawings and DataSheets.
Electrical or key interlocks will be provided where shown on one line diagrams and
Data Sheets to accomplish the function called for.
Each circuit breaker will be provided with a local open – close control switch and red -green – yellow lights to indicate open, close and fault or trip breaker positions on thefront of unit panel. Provision in control wiring will be made for breaker remote "open-close-trip" functions.
Circuit breaker control voltage will be 125 Vdc or as indicated on Data Sheets and willbe supplied by the BHPB. Close and trip circuits for each breaker will be separatelyfused. Fuse block will be dead front, pull-out type, which provided the control powerdisconnecting means.
When specified on Data Sheets, circuit breakers will be furnished with "capacitortripping devices" which rectify alternating current and stores resulting direct current incapacitors to provide a reliable source of energy to trip the circuit breaker without needfor batteries and chargers.
Each breaker will have padlock type lockout provision.
Protection devices will be in accordance with Data Sheets and one line diagrams.
Surge protection equipment will be furnished and installed as indicated on referencedrawings and Data Sheets. Surge arrester ratings and characteristics will be adequateto meet system and equipment protection requirements.
When required, a transition section should be provided to interconnect the switchgearbus section with the motor controller bus section.
Each assembly will consist of metal-enclosed, free-standing, vertical and dead-frontsteel structures containing power buses, a ground bus, controllers, necessary auxiliarycontrol devices, specified instrument transformers, relays, meters and selector andinstrument switches.
A single vertical section will have a maximum of two induction motor controllers; or onesynchronous motor controller; or one feeder controller.
Barriers will be provided between vertical sections, between each low voltage controland the high voltage compartment, and between the main horizontal power bus andthe controller compartments.
Each assembly will be suitable for the future extensions on each end unless otherwisenoted. If motor controllers are part of the switchgear, they will be bus connected toform one complete line-up.
Meters, instruments, selector switches, position indicating lights, etc., will be mountedon the front of the controller.
Controllers will be NEMA Class E2 using R rated current-limiting fuses.
E2 Controllers will have a minimum 3-phase symmetrical interrupting capacityaccording to one line diagrams and Data Sheets.
The contactors will be vacuum or SF6 or as specified on Data Sheets, magneticallyheld type. The contactors for feeder controllers will be mechanically latched type. Thecontactors continuous current, maximum voltage and 3-phase symmetrical interruptingratings shall be as indicated on Data Sheets.
Power fuses will be current-limiting and self-protecting type with visible fuse conditionindicator. All fuses will be easily inspectable or replaceable without controller
disassembly. Fuses will operate during the first half cycle on fault conditions and willnot expel gases or foreign matter.
Controller will be wired and assembled as complete, totally enclosed and self-supporting units.
Controllers will be completely front wired. Controller assemblies will be suitable forback-to-back or back-to-wall installation. Cable entries will be as indicated on the Data
Sheets.
Sufficient space will be allowed in each controller and incoming auxiliary unit formaking termination with stress relieving cones on incoming and outgoing shieldedpower cables.
Solderless cable lugs for conductors will be furnished with each controller. Size andquantity per phase will be as shown on the Data Sheets.
Each controller will have a lockable, externally-operable, gang-operated high voltage
isolating means with position indication. Isolating means will be capable of interruptingthe no-load current of the control-circuit transformer supplied with the controller.
Interlocking will be provided by mechanical means or by a combination of mechanicaland electrical means and will provide following features:
• Prevent the isolating means from being opened or closed unless the line contactoris open.
• Prevent the opening of a high voltage compartment door when the isolating meansis closed.
• Prevent the isolating means from being closed when any high voltagecompartment door of the controller is open.
Padlocks provision to permit operating handle for the high voltage compartment doorswith one padlock in the closed position and three padlocks in the open position.
Each controller will provide a positive grounding of the controller when isolating meansis opened. Such means will be connected to the ground bus.
Line side stab opening will be automatically covered by a screen shutter when carriageis withdrawn in order to prevent accidental contact with line high voltage terminals.
A safe inspection position will be provided to allow inspection or maintenance withoutcomplete removal of the controller carriage from the compartment.
Each motor controller will be wired for remote control and will have a door-mounted 2-position maintained "REMOTO"-"LOCAL" selector switch when specified on the DataSheets or reference drawings. When selector switch is in "REMOTO" position, it willallow remote control switch to activate the closing circuit as required. However, the
remote switch will be able to activate the open circuit independently of the selectorswitch.
Control power will be provided by a dry-type control power transformer (CPT) havingfuse protected primary and secondary. CPT will be located in each controllercompartment and will be automatically disconnected from the high voltage whencontroller carriage is withdrawn or isolating switch opened. Control power transformerwill be sized to have 150% of the capacity needed for all the control devices beingsupplied power.
Provision will be included for testing the operation of main contactor and low voltagecontrol circuits from an external source. Power to the main power bus through controlpower transformer will be prevented by an interlock or other safety device.
Each controller will be equipped with a minimum of four auxiliary contacts; twonormally open and two normally closed in addition to auxiliary contact required forcontactor and motor space heater control. These four spare contacts will be wired toan accessible terminal block for the BHPB use.
Motor controller protective relays, auxiliary relays, meters, permissive relays, switches,etc., will be supplied as shown on the Data Sheets and one line diagram.
Each controller will be provided with 3 current transformers of sufficient volt-ampere
capacity to meet the requirements of all the devices connected to them. Currenttransformer will be 5-ampere secondary rating, a primary rating as shown on the DataSheets and one line diagrams, and accuracy suitable for the type and quantity ofdevices connected to it. The current transformers will be selected so that they do notsaturate for a minimum value of fault current equal to 20 times contactor interruptingrating considering the burden of the relays.
The specific requirements for feeder controllers are as follows:
• The controller will be provided with latch-type contactors to maintain the power
continuity during voltage drops.• Each feeder controller will be provided with 2 door-mounted "LOCAL" pushbuttons
along with the associated indicating lights. One pushbutton will have a nameplatelabeled "ABRIR" and the other "CERRAR". A green light, mounted above thepushbutton “ABRIR”, will have a nameplate labeled "ABIERTO". A red light,mounted above the pushbutton “CERRAR”, will have a nameplate labeled"CERRADO".
• Additionally, means will be provided for manually tripping the latched contactor ofeach feeder controller from outside without opening the door. It will have a
nameplate labeled "APERTURA MANUAL".• Protection devices will be provided as indicated on one-line diagrams and Data
Sheets.• Current limiting fuses for interrupting short-circuit fault currents
5.5.1 Provisions for Motor Space Heaters
Power for motor space heaters will be controlled by normally closed auxiliary contactson the motor contactor.
Each ungrounded conductor of the heater power supply will be assigned 1 auxiliary
contact.
Additionally, each ungrounded space heater lead will be fused and terminated onterminal blocks.
The voltage and wattage of the space heaters for each motor will be shown on theData Sheets.
Power for motor space heaters will be supplied from an external power source.
Each motor space heater circuit will be provided with a door-mounted switch with whitelight to indicate the heaters are energized.
5.6 Load Interrupter Fused Switches
The load break fused switches will be 3 pole, manually group-operated type. Eachswitch will be rated for continuous operation and will have withstand capability ofmomentary stress according to system fault capacity as specified on Data Sheets.Switches will be capable of interrupting the full load current of the associatedtransformer.
The fuse compartment door will be mechanically interlocked with the switch, so thatthey cannot be removed unless the switch is opened.
Each switch will be contained in a metal enclosed, free-standing enclosure. Switchhandle will be operable from the front. Switch mechanism will be of the stored energytype not dependent upon incremental motion of operating handles. Switchcompartment will have a sight window for visual inspection of switch contact.
Potential and current transformers will be furnished in quantities and locations asspecified on one line drawings and Data Sheets. The transformers will have, as aminimum, sufficient capacity for their connected burdens.
5.7.1 Potential Transformers
Potential transformers will have standard metering accuracy class according toapplicable codes and standards.
High and low voltage windings of potential transformers will be fuse protected. TheHigh voltage fuses will be current limiting type with interrupting capacities to match
switchgear ratings. The low voltage fuses will be coordinated with high voltage fusesand supplied in quantities shown on drawings. MCB's are acceptable on low voltageside if coordinated with high voltage fuses.
Potential transformers will be mounted on a drawout type assembly, which willdisconnect both primary and secondary sides in withdrawn position.
5.7.2 Control Power Transformers
Control power transformers will have adequate capacity for their connected burden
and will have a minimum of 25% spare capacity to operate external auxiliary controldevices.
Transformers will be fuse protected on the primary and secondary as required byapplicable codes and standards.
5.7.3 Current Transformers
Current transformers will be mounted as an integral part of switchgear and will havestandard metering and relaying accuracy class according to latest applicable codesand standards.
Current transformer's mechanical and thermal ratings will be coordinated with shortcircuit ratings of the system.
5.7.4 Indicating Instruments and meters
All indicating instruments and meters will be of the flush mounting, back connectingtype, provided with facilities for testing in position, digital type with an accuracy of ±
1.5% or better. The Instruments will be calibrated for use with their associatedpotential and current transformers.
Each instrument or meter will be microprocessor-based device, completely digital,providing metering and register functionality, with multi function intelligent electronicdevices (IED’s). These devices will provide ethernet 10/100 MBPS, UCA2/IEC 61850communication and will be connected to a SCADA network for the transmission ofinformation.
Watt-hour meters will consider 15-minute demand periods.
5.7.5 Control Switches
Control switches, where called for, will be of rotary, switchboard type with all contactmechanisms behind panels.
Switches will have ample contact stages with minimum of two spare contacts andsuitable cam arrangements to perform breaker "trip-close" functions with spring returnto neutral position feature. Each contact will be of readily removable, self-cleaning,wiping action type with adequate insulation and surface area. Slip contacts will beprovided for electrical interlocking and alarms as required.
5.7.6 Indicating Lights
All indicating and pilot lamp assemblies will be switchboard type, full voltage Multiledlight units, 125 Vdc/120 Vac, with color caps. Led lamps and caps will be replaceablefrom the front of panels. Cap color will be red to indicate breaker "closed", green forbreaker "open" position and yellow to indicate “fault” or “trip”.
5.7.7 Protective Relays
The relay contacts will be rated for 125 Vdc.
Each protective relay will be microprocessor-based device, completely digital providingprotection, metering and register functionality, with multi function intelligent electronicdevices (IED’s).
The IED’s protective relays will provide ethernet 10/100 MBPS, UCA2/IEC 61850 forthe communication to a SCADA network of all relay information.
Unit nameplates will have 12-mm height writing in Spanish with unit legends indicatedon the reference drawings and data sheets. Approval is required for nameplate
wording and arrangement.
Instruments and control switches, whose function is not identified by self-containednameplates, will be identified with a 25 mm x 75 mm engraved nameplate using 6 mmheight writing.
5.9 Shop Painting
Unless otherwise noted, final color, surface preparation and corrosion protectivecoating will be Manufacturer’s standard practice for the environmental conditionsspecified.
5.10 Special Tools and Appliances
One complete set of special tools and/or appliances for installation and maintenancepurposes will be furnished with equipment.
5.11 Accessories
In addition to other devices specified herein, accessories to be furnished will include,as a minimum, the following:
• One lifting device for installing and removing the carriages, truck or movingportions (One device per each electrical room, the final quantity will be indicated onData Sheets and Purchase Order).
• One insulated fuse puller, if required, for power and control fuses (One puller perassembly).
• Test plug unit for testing any drawout relay or meter.• One breaker test cabinet for testing drawout circuit breaker outside the enclosure.• One spare set of fuses of each different type and rating.
6.0 INSPECTION AND TESTING
Tests will be conducted on each assembly according to applicable requirements ofcodes and standards described herein and appropriate test documentation will besubmitted to the BHPB. Supplier will give BHPB notice in writing not less than 4 weeksprior to tests, in order to arrange for an inspector to witness parts or all of the tests.
In addition, Manufacturer will furnish certified test reports for factory load andtemperature rise of bus members and other parts, which carry continuous current.
All deficiencies observed during the testing process will be documented and correctedprior to shipment.
Authorized representatives of the BHPB will be allowed free access to Supplier's shopat all times for purposes of inspection or obtaining information on progress of the work.
Material improperly fabricated or detailed, so that its installation in the field requiresextra work, will be responsibility of Supplier, who will pay entire cost of corrections ofshop errors and replacement of incorrectly fabricated parts.
Supplier will include with his bid a list and description of his standard tests performedduring equipment fabrication including the final tests.
7.0 DOCUMENTATION
Supplier will provide all items listed in the "Bidder Drawing and Data Commitments"(BDDC), attached to the TRFQ.
All drawings, data and transmittals will be in accordance with the instructions
described on BDDC.
Supplier will submit a list of exceptions to this specification with his proposal. Supplierwill be responsible for completeness of exceptions taken. If no exceptions are listed itwill be assumed that specification as written will be met completely.
8.0 PREPARATION FOR SHIPMENT
Packing and preparation for shipment will be according to project packing instructions.
Each item will be suitably packed and/or crated for shipment.
Each separate item or assembly will be tagged with a durable metal tag embossedwith the appropriate equipment number, purchase order number and description asdesignated in the "Procurement Documents".
Equipment will be provided with supports of sufficient strength to permit hoisting withsafety. Location of lifting points will be clearly shown on Supplier's drawings.
Equipment will be protected against the entrance of moisture and/or dust as the resultof ocean shipment and outdoor storage at site.
9.0 SHIPPING INFORMATION
The Supplier will provide transport drawings for each and every piece of taggedequipment. Transport drawings will include the outside dimensions, gross weight, netweight, center of gravity, lifting lugs or sling points, skid or platform and hood (if any).
Rated voltage for Switchgear [kV] 13.8Rated voltage for Motor Controller [kV] 4.16
Voltage variation [+/- %] 10
Phase [ph] 3
Frequency [Hz] 50
Frequency variation [+/- %] 5
Voltage unbalance [+/- %] 1
Short Circuit Capacity at 13,8 kV [MVA]750 (To be confirmed byAMEC)
Short Circuit Capacity at 4,16 kV [MVA]350 (To be confirmed byAMEC)
Grounding type Neutral resistor 20 A, 10 sec.
5.00 AUXILIARY SUPPLY
Power source supplier External by BHPBPower source 400-230V / 50 Hz / 3 phases
Circuit Breaker Control source supplier External by BHPB, 125 Vdc
Contactor Control source Internal by Vendor, 120 Vac
6.00 GENERAL ELECTRICAL REQUIREMENTS
Rated voltage at 3200 m.a.s..l for Switchgear [kV] 13.8Rated voltage at 3200 m.a.s..l for MotorController [kV] 4.16
Voltage derating factor (ANSI standard) 0,783
Rated frequency [Hz] 50
BIL at 3200 m.a.s.l. for Switchgear [kV] 150
BIL at 3200 m.a.s.l. for Motor Controller [kV] 95Rated power freq. withstand voltage
at 3200 m.a.s.l. for Switchgear [kV] 36Rated power freq. withstand voltageat 3200 m.a.s.l. for Motor Controller [kV] 20Rated lightning impulse withstand voltage forSwitchgear [kV] 150Rated lightning impulse withstand voltage forMotor Controller [kV] 95
MVA class for Switchgear [MVA] 750
MVA class for Motor Controller [MVA] 350
7.00CONSTRUCTIVE REQUIREMENTS FORSWITCHGEAR
Installation Indoors
Enclosure NEMA 1A (NEMA 12)
Type Metal-clad7.10 Busbar
Type Single busbars
Sections By Vendor
Busbars material Insulated Copper
Rated current [A] 600
Rated voltage [V] 13800
Rated power frequency withstand voltage [kV] 36
Rated lightning impulse withstand voltage [kV] 150