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Key codes : Substation, Electrical room, Switchroom, Power, Technical floor, Pressurisation, Air-conditioning, Lighting, Fire detection, Earthing, Cabling. F E D C
B A 0
Rev
R. MEINHARDT
R. MEINHARDT
Approved CTEC
LAFARGE CENTRE TECHNIQUE INTER-UNITES LIsle dAbeau Parc de Chesnes B.P. 70 F-38291 ST QUENTIN-FALLAVIER Cedex Phone : + 33 474 82 16 16 / Fax + 33 474 94 30 07 ASIA TECHNICAL CENTRE Level 3,Wisma Lafarge N 2 Jalan Kilang 46050 PETALING JAYA SELANGOR DARUL EHSAN MY-MALAYSIA Phone : + 603 77874800 / Fax : + 603 77874890 Reproduction & usage strictly forbidden without Lafarge th explicite agreement (Law March 11 , 1957)
LAFARGE CENTRE TECHNIQUE EUROPE CENTRALE Gumpendorfer Strasse 19-21, A-1060 WIEN, Postfach 264 Phone : + 43 1 811 42 0 / + 43 1 811 42 44 09
DEPARTMENTAL SUBSTATIONS
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STD.002.U04
1/22
DEPARTMENTAL SUBSTATIONS
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Rev.
STD.002.U04
2/22
CONTENT
1.
1.5. 2.
APPLICABILITY.....................................................................................................................4 ASSOCIATED SPECIFICATIONS .........................................................................................4 APPLICABLE STANDARDS ..................................................................................................4 LOCAL CONDITIONS............................................................................................................4 GLOSSARY...........................................................................................................................4
CIVIL WORKS..............................................................................................................................6 GENERAL DESIGN...............................................................................................................6 2.2. FINISHING ASPECTS AND PAINTING .................................................................................6 2.3. DOORS .................................................................................................................................7 2.3.1. Common requirements ...................................................................................................7 2.3.2. Electrical rooms, staff access door..................................................................................7 2.3.3. Electrical rooms, door for emergency exit and equipment bringing in..............................7 2.3.4. Transformer rooms, staff access and equipment bringing in doors .................................8
2.1.
3. 4.
TECHNICAL FLOOR....................................................................................................................8 AIR-CONDITIONING AND PRESSURISATION ...........................................................................9 4.1. 4.2. 4.3. AIR-CONDITIONING .............................................................................................................9 PRESSURISATION .............................................................................................................10 POWER SUPPLY ................................................................................................................10 LIGHTING............................................................................................................................11 FIRE DETECTION...............................................................................................................11 CONTROL AND SAFETY DEVICES ...................................................................................12 EARTHING ..........................................................................................................................12 CABLING.............................................................................................................................12 SAFETY EQUIPMENT.........................................................................................................12
5.
6.
6.2. 6.3.
6.4.
7. 8. 9.
DEPARTMENTAL SUBSTATIONS
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STD.002.U04
3/22
1. GENERAL POINTS
1.1. APPLICABILITY
This specification is applicable to any departmental substation, i.e. any electrical room feeding and controlling a plant department. It is also applicable to the incoming substation feeding the departmental substations with some additional requirements mentioned in specification STD.002.U03.
1.5. GLOSSARY
ACC CCR Department Auxiliary Control Centre. Central Control Room. Functionally linked sub-process stage for a given process stage and a given line (please refer to specification STD.002.U01, section 1.1). Examples are : Raw Mill 2, Kiln 1, Cement Mill C, Emergency Shut-Down of a given department initiated by pressing an emergency shut-down push button installed in this department or in the CCR. It initiates a quick shut-down of each sequence and trips the contactors and MV circuit breakers of all users of the department.
DESD
DEPARTMENTAL SUBSTATIONS
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STD.002.U04
4/22
Electrical room
Room of a substation where electrical switchgear and electrical equipment are installed to be kept in clean and cool ambiance ; also called Switchroom. Motor Control Centre. ( LV switchboard controlling motors and 3-phase users ) Medium voltage (above 1000 V and not exceeding 36 kV) Medium voltage emergency shut-down (tripping the departmental MV switchboard) Power Control Centre. ( LV distribution switchboard feeding MCCs or other 3-phase users ) The Site Specification is a technical specification complementing the Electrical Standard Specifications and describing, for a given site, its particulars such as : Local conditions (climate, altitude, earthquakes, ) Voltages and frequency of power and control circuits Local regulations Technical requirements specific to the site Approved deviations from the Electrical Standard Specifications if required.
MCC
MV MVESD
PCC
Site Specification
Substation
Place where electrical equipment are concentrated, installed in electrical room(s)/switchroom(s) and transformer room(s). Room of a substation where electrical switchgear and electrical equipment are installed to be kept in clean and cool ambience ; also called Electrical Room . Room of a substation where power transformers are installed. Uninterruptible Power System. Variable Speed Drive.
Switchroom
DEPARTMENTAL SUBSTATIONS
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STD.002.U04
5/22
2. CIVIL WORKS
B
Install a thermal insulation under the ceiling of the whole substation if this ceiling is just under a roof. In the electrical room this insulation shall be covered with panels made of a soundabsorbing material.
DEPARTMENTAL SUBSTATIONS
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STD.002.U04
6/22
Materials used shall be non flammable and shall be certified by the National Fire Protection Association ( NFPA ). Fill in any hole or space through which the dust could penetrate, in order to make the pressurisation system efficient. Paint all the substation internal walls with a semi-glossy paint of light shade. Paint the concrete slab of the transformers room and of the airlock with a glossy paint of similar shade specially designed for concrete surfaces.
2.3.3. Electrical rooms, door for emergency exit and equipment bringing in
Except in small electrical rooms, a second door shall be installed at the other end of this area to facilitate staff evacuation in case of hazard, and also for bringing in the equipment.
DEPARTMENTAL SUBSTATIONS
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STD.002.U04
7/22
This door shall be identical to the inside door of the airlock here above mentioned but, in order to bring in the equipment easily, it shall be surrounded with metallic panels fixed by bolts or by locks. The passage shall be 2.80 m high and 1.20 m broad when panels are removed. This door shall not be equipped at outdoors side with any handle or lock entry so that entering in this area will be by the airlock only (but at indoors side with a panic bar). This door being a single barrier to dust ingress (the airlock is a double barrier), it shall be really dust tight. As it will be used in case of urgency only, thin silicon seals can be used, easy to be broken in case of emergency. The door frame shall border the door on its 4 sides, including a bottom section that will keep between the ground and the door a free space of 30 mm minimum to avoid that a small stone could block the door. For small electrical rooms, staff entry and equipment bringing in will be by the same access; this single access will be an airlock with both doors surrounded with metallic panels as explained here above.
Note :
Note :
3. TECHNICAL FLOOR
A technical floor shall cover all the electrical room. It shall be designed for an even load of 1500 daN/sqm (15 kN/sqm) and a local load of 300 daN/sqm (3 kN/sqm) on a 25 mm by 25 mm area. It shall be made of modular panels (600 mm x 600 mm). Each panel shall be made of: a high density clipboard panel, at least 30 mm thick; a high pressure laminated surface; a PVC edge, or better aluminium, crimped around panel sides.
DEPARTMENTAL SUBSTATIONS
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STD.002.U04
8/22
Panels shall be non flammable and shall be certified by the National Fire Protection Association (NFPA) or at least comply with ASTM standards. Panels shall be supported on a steel structure made of adjustable jacks and mobile supporting steel sections. Each steel item shall be protected from rust by hot dip galvanisation. Jacks shall be fixed to the base ground by bolts or glue. Their length shall be so that technical floor finish surface be at not less than 600 mm above supporting concrete slab. When necessary, additional steel sections shall be installed for reinforcing panels placed in cantilever, in order to keep resistance to here above mentioned loads. Technical floor installation is explained in section 10, drawing 5. A suction disc for lifting technical floor panels shall also be supplied in each electrical room as specified in section 6.4. For a revamping, if it is not possible to install a technical floor, the electrical rooms ground shall be covered with a plastic material (tiles or bands) limiting dust emissions and reducing electrical shock hazards by insulating operators from the ground, or at least with insulating mats on front and back of each cabinet.
Note : B
4.1. AIR-CONDITIONING
Air-conditioning system for the electrical rooms shall be reliable and simple. Priority shall be given to reliability rather than to performance. In countries with a hot climate (when average day/night temperature exceeds 35 C during more than 7 days a year) double air-conditioners shall be used, one unit only being able to keep internal temperature under here after mentioned maximum temperature. Air-conditioning units will use water cooled condensers or be of the "split system" type with an air cooled condenser installed outdoors. Electrical equipment shall be protected IP55. Air-conditioning system shall be dimensioned to keep into the Electrical Room a temperature lower than or equal to 28 C . This requirement is for limiting the temperature inside the cabinets so that this average temperature over a period of 24 h does not exceed +35 C as required by standard IEC 60947-1. The air-conditioning power installed shall not be less than 100 W/m3 of room volume; it shall be sufficient to evacuate: the heat dissipated in the room, the heat flowing through the walls, ceiling, floor of the room, the heat of the air injected in the room by the pressurisation system.
DEPARTMENTAL SUBSTATIONS
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STD.002.U04
9/22
If batteries of lead-acid type are installed in the electrical room the ambient temperature of this room shall be limited to 20 C . Indeed, a temperature of 28 C would reduce consid erably its lifetime: raising the temperature from 20 C to 30 C divides by 2 the lifetime of a lead-acid battery. An alternative solution could be to install the battery in a separate room kept at 20 C maximum as it is common in incoming substations for feeding the HV switchgear control circuits. A heating system shall also be installed, if necessary, to keep the temperature above 15 C. Cool air shall be distributed from upside. Back air shall flow under the technical floor, passing through this floor by louvres to be installed at the opposite corner of the room to the airconditioning unit. The Supplier will decide whether air distribution ducts should be installed for cool air. Please also refer to section 10, drawing 6.
4.2. PRESSURISATION
Pressurisation of the electrical rooms is to avoid or limit dust ingress. This system shall be capable of keeping into the room a 20 mm water column (200 Pa) overpressure with a minimum air flow equal to 2 times the room volume each hour. This capability will be demonstrated by submitting to the Owners approval appropriate technical data (fan curve) about proposed equipment. Pressurisation equipment shall be mounted through the wall with an access for maintenance from the outside. It shall include: a static filter with an easy access for maintenance, generously dimensioned to avoid maintenance intervals shorter than three months. This filter shall stop any sedimentable dust particle (size above 10m) and be of class EU4 (90 % weight efficiency). Self cleaning filters shall be proposed by the Supplier as an option; a low noise fan running at 1500 RPM at the maximum with a motor protected IP55; a fresh air inlet duct in the electrical room. The pressurisation system shall automatically be switched off in case of fire (please refer to section 5.2). Please also refer to section 10, drawing 7.
DEPARTMENTAL SUBSTATIONS
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Rev.
STD.002.U04 10/22
Automatic fire detectors: ionisation fire detectors shall be installed: in the electrical rooms above technical floor; in the electrical rooms under technical floor, protected by a wiremesh cover; in the transformer rooms above transformers. The numbers of detectors shall be adapted to volumes to be monitored.
Non automatic fire detectors: 1 push button protected by a breaking glass (IP65) shall be installed close to the access doors to the transformer rooms. Annunciators: 1 red lamp flashing lamp (IP 65) and 1 amovible signal, 100dB at 1m Monitoring: all the detectors of each substation shall be connected to a common monitoring panel installed in the Central Control Room. Each substation will be a separate monitoring area on this panel. Integration in an existing fire detection system: if the plant is already equipped with a general fire detection system the present supply shall be integrated into the existing system and fires annunciated on the existing general fire monitoring panel in the CCR. The fire detection system shall automatically switch off the pressurisation fan in case of fire (please refer to section 4.2). Test: each detector shall be tested regularly in accordance with standards applicable on the site. Equipment required for performing periodic tests is included into the Supply.
DEPARTMENTAL SUBSTATIONS
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STD.002.U04 11/22
6.2. EARTHING
As required by specification STD.002.U12, the General Electrical Supplier has to earth the metallic structure supporting the technical floor. This shall be performed by connecting each third supporting jack to an insulated 16 sqmm copper cable. This cable shall in turn be connected at both ends to the plant earthing grid or to the main earthing conductor in 2 different points.
6.3. CABLING
Cables shall be installed in accordance with specification STD.002.U12 as well as with principles given in section 10 drawing 4. At the end of cabling any access into the departmental substation shall be filled in with fire resisting material as required by specification STD.002.U12. It is reminded that no cable should be installed directly on the ground. This is also valid for cables running under the technical floor.
Note :
DEPARTMENTAL SUBSTATIONS
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STD.002.U04 12/22
- 1 voltage tester up to 22 kV - 1 MV rescue insulated stick perch. warning signs (in local language), suction disc for lifting technical floor panels; The Supply shall also include the fire extinguishers as required by applicable regulations, except if these extinguishers are part of the civil work contract or of a general fire protection contract.
7. DOCUMENTS
The Supplier shall supply following documents : Substation general lay-out Civil works guide drawing Cable routings lay-out Air conditioning and pressurisation systems: Air conditioning calculation note; Pressurisation system technical data; General lay-out; Electrical diagrams; Erection and maintenance leaflets. Lighting design documents Fire detection system design documents. These documents shall comply with the requirements of specification STD.002.U02, Preparation of Electrical Documents, except for leaflets and standard documents from the manufacturers.
8. GUARANTEE
Guarantee on equipment supplied shall cover a minimum period of 24 months after Provisional Acceptance, with a maximum of 30 months after the equipment has been delivered at site.
9. DATA SHEET
Values to be mentioned in boxes shaded and marked with sign the Owner or by the main Contractor.
are to be given by
DEPARTMENTAL SUBSTATIONS
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STD.002.U04 13/22
CUSTOMER: PROJECT: DATA SHEET AIR-CONDITIONING / PRESSURISATION EQUIPMENT: Air-conditioning system 1 Equipment type 2 Manufacturer 3 Stand-by device 4 Electrical power 5 Full load cooling capacity 6 Air flow 7 Design with ducts, louvres, deflection grids 8 Condensation type 9 Water flow (if water cooling) 10 Humidity control system 11 Dimensions 12 Weight 13 Heater power (if required) Pressurisation system 14 Filter type 15 Filter cleaning system type 16 Dust storage system 17 Filter weight efficiency 18 Operpressure maintained to : 19 Air flow 20 Electrical power 21 Fan sound pressure 22 Dimensions 23 Weight 24 Deviations from this specification
Note : The Supplier is requested to fill in a data sheet for each type of equipment proposed and to return it with his proposal.
DEPARTMENTAL SUBSTATIONS
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STD.002.U04 14/22
EC
EC
VS1
VS2
S U - E le c tric a l ro o m e x te n s io n 1700 MC MC MC MC MC MC MC MC MC MC
12000
e xte n s io n UP AC
AM DM
1500
E m b e d d e d P ip e s
AU
Pressurisation
DH
DH
DH
DH
DH
Cable trenches
Cable trenches
500 min.
s e e D e ta il 1 LT A B CP1
3300
- s e e d e ta il 2
A irlo c k
- s e e D e ta il 4 - s e e D e ta il 2 D e ta il 1 : A - S m o k e d e te c to r
T y p ic a l B o a rd s D im e n s io n s
Code MC AC A M /D M UP DH TF1 TF2 TF3 D e v ic e MCC ACC M a rs h a llin g B o a rd UPS M V S w itc h b o a rd 1 6 k V A a u x . T ra n s f. 1 0 0 0 k V A -T ra n s fo rm e r 2 0 0 0 kV A -T ra n s fo rm e r L e n g th (m m ) 1000 1200 1200 600 750 520 1850 2120 D e p th (m m ) 400 400 400 700 1220 342 1000 1180 W e ig h t kg ) 96 2300 3700 C ode CP1 CP2 VS1 VS2 EC LT AU D e vic e M V -C a p a c ito r L V - C a p a c ito r V S D - 400kW V S D - 1400kW W e ig h fe e d e r b o a rd L ig h tin g D istrib . B o a rd A ir-c o n d itio n in g s y s te m
FA
s e e D e ta il 5
A cc e s so rie s
M V E m e rg e n c y S h u t D o w n p u s h b u tto n (M V E S D )
FA
F ire a la rm p u s h b u tto n
DEPARTMENTAL SUBSTATIONS
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STD.002.U04 15/22
DRAWING 1 (Continued)
Detail 3: Screwed Plate extensions around door to ensure easy material access Detail 4: Door with Louvre for Transformer Room Detail 2: Door Standard Dimensions: 900*2100
2100
2800
DEPARTMENTAL SUBSTATIONS
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STD.002.U04 16/22
Thermal Insulation
Thermal Insulation
Airlock
SECTION B-B
TF2 CP1
TF3
See Detail 5
See Detail 6
Detail 5
Rails Anchoring
Detail 6
frame for retaining leaking oil Seal
DEPARTMENTAL SUBSTATIONS
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STD.002.U04 17/22
Thermal Insulation
MV Switch-Board
MCC
100
100
600
DRAWING 3 Alternative Solution (When there are risks of cable room's flooding)
MV Switch-Board
MCC
Side Walk
1000
600
DEPARTMENTAL SUBSTATIONS
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3000
3000
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Rev.
STD.002.U04 18/22
DRAWING 4
EC
EC
VS1
VS2
SU - Electrical room
D C
extension MC
Embedded pipes
MC MC
MC MC
MC
MC
MC
UP
AM AC DM
AU
DH
DH
DH
DH
DH
Cable trench
Cable trench
Cable trench
LT
CP1
TF2
TF3
SU - Transformer room
Lighting fixtures
LV - Cable tray
Legend 3: Field bus cables to be installed in steel pipes unless they have a metal armor
DEPARTMENTAL SUBSTATIONS
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Cable trench
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STD.002.U04 19/22
DRAWING 4 (Continued)
SECTION C-C
Embedded pipes from " Electrical Room " to "Production Area " (field)
Detail 7
900 150 200 200 200 150 Concrete Electrical Room Pipes end to be filled in after cables installation Electrical Room
600
300
1000
SECTION D-D
Plant
Sidewalk 600
Cable ladder
SECTION E-E
Plant
Sidewalk
DEPARTMENTAL SUBSTATIONS
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STD.002.U04 20/22
45
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DRAWING 5
600
600
30mm Thickness
Adjustable Jacks
16mm
600
DEPARTMENTAL SUBSTATIONS
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600
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STD.002.U04 21/22
DRAWING 6
Air Conditioning
Thermal Insulation
Cooled Air Flow
DRAWING 7
Pressurisation
Fresh Air
Thermal Insulation
DEPARTMENTAL SUBSTATIONS
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STD.002.U04 22/22