Electrical Standarts

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POWER CONTROL CENTRES,MOTOR CONTROL CENTRES

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LIST OF ELECTRICAL STANDARD SPECIFICATIONS

01 Codes for electrical equipment

02 Preparation of electrical documents03 Incoming substations04 Departmental substations05 Medium voltage switchboards06 Power transformers

07 Power control centres, motor control centres

08 Large motors09 Small motors10 Starters11 Variable speed drives12 Erection, cabling, earthing connections, lightning protection13 Production and distribution of auxiliary voltages

14 Electrical cabinets and marshalling cabinets15 Instrumentation16 Process Control System : equipment and configuration17 Process Control System: application software and integration18 Lighting and power outlets19 Electrical devices for mechanical equipment20 Earthing grid21 Process Control System : basic functional objects22 Visible Cut-off Switches23 Incoming transformers

Key codes: Low voltage, Power, Motor Control Centre, MCC, Cabinet

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A 21/10/05 General revision I. MOCANU M. MAHAUX

0 07/10/02 Document edition I. MOCANU M. MAHAUX

Rev Date Scope of revision Issued Approved CTI ApprovedCTEC

LAFARGE CENTRE TECHNIQUE INTER-UNITESLIsle dAbeau Parc de Chesnes B.P. 70F-38291 ST QUENTIN-FALLAVIER CedexPhone : + 33 474 82 16 16 / Fax + 33 474 94 30 07

LAFARGE CENTRE TECHNIQUE EUROPE CENTRALEGumpendorfer Strasse 19-21,A-1060 WIEN, Postfach 264Phone : + 43 1 811 42 0 / + 43 1 811 42 44 09

ASIA TECHNICAL CENTRELevel 3,Wisma Lafarge N2 Jalan Kilang46050 PETALING JAYA SELANGOR DARUL EHSANMY-MALAYSIAPhone : + 603 77874800 / Fax : + 603 77874890

Reproduction & usage strictly forbidden without Lafarge

explicite agreement (Law March 11th

, 1957)

ELECTRICAL STANDARD

SPECIFICATION


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CONTENT

1. GENERAL REQUIREMENTS 4

1.1. APPLICABILITY 41.2. APPLICABLE STANDARDS 41.3. LOCAL CONDITIONS 41.4. GLOSSARY 41.5. SIGNS USED 41.6. ENCLOSURE AND DEGREE OF PROTECTION 51.7. RATED VOLTAGES 5

1.7.1. Main voltage......................................................................................................................51.7.2. Auxiliary voltages..............................................................................................................5

1.8. RATED INSULATING VOLTAGE 5

1.9. RATED CURRENTS 51.10. SHORT CIRCUIT WITHSTAND STRENGTH 6

2. SWITCHBOARD CONSTRUCTION 6

2.1. COMMON REQUIREMENTS 62.1.1. General arrangement........................................................................................................62.1.2. Switchboard structure........................................................................................................62.1.3. Incoming circuit(s).............................................................................................................72.1.4. Busbars............................................................................................................................. 72.1.5. Control and measuring circuits..........................................................................................82.1.6. Remote Input/Output modules...........................................................................................82.1.7. Wiring................................................................................................................................8

2.1.8. Labels................................................................................................................................92.2. DRAW-OUT / FIXED TYPES 9

2.2.1. Draw-out type....................................................................................................................92.2.2. Fixed type........................................................................................................................10

3. POWER SWITCHGEAR 11

3.1. INCOMERS AND BUS-TIE BREAKERS 113.2. OUTGOING CIRCUITS 11

4. CONTROL SWITCHGEAR AND MEASURING DEVICES 12

4.1. CONTROL CIRCUITS 124.2. PROTECTIONS 13

4.3. MEASURING DEVICES 14

5. PCC/MCC SUPPLYING VSDS 14

6. POWER FACTOR CORRECTION UNITS 15

7. DOCUMENTS 17

7.1. DOCUMENTS TO BE SUPPLIED BY THE OWNER 17


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7.2. DOCUMENTS TO BE PREPARED BY THE SUPPLIER 177.3. DOCUMENTS TO BE SUBMITTED WITH THE OFFER 18

8. FACTORY TESTS 18

9. GUARANTEE 19

10. DATA SHEETS 19

11. SWITCHGEAR SELECTION TABLES 22

11.1. SWITCHGEAR SELECTION FOR 400 V MOTORS USING LINE STARTERS 2211.2. SWITCHGEAR SELECTION FOR 500 V MOTORS USING LINE STARTERS 24

12. DIAGRAMS 24


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1. GENERAL REQUIREMENTS

1.1. APPLICABILITY

This specification is applicable to Power Control Centres (Low Voltage Distribution Boards) aswell as to Motor Control Centres operating in 3-phase AC under a voltage not exceeding 1000 V.

1.2. APPLICABLE STANDARDS

The panels shall comply with the requirements of IEC and ISO standards. In particular, they shallbe prefabricated, type-tested assemblies according to IEC 60439-1 standard.

1.3. LOCAL CONDITIONS

Local conditions are given in the Site Specification. Equipment subject to this specification will beinstalled in electrical rooms protected from the dust. The ambient air temperature will not exceed+ 40C nor be less than - 5C and its average over a period of 24 h will not exceed + 35C.

If required by climatic conditions, anti-condensation heaters shall be installed.

1.4. GLOSSARY

ACC Auxiliary Control Centre

MCB Miniature circuit breaker

MCC Motor Control Centre

PCC Power Control Centre

PCS Process Control System

UPS Uninterruptible Power Supply

VCS Visible Cut-Off Switch

VSD Variable Speed Drive

1.5. SIGNS USED

Asign in the margin will mark up in the text of this specification each clause to be mandatorilyspecified by the Site Specification.


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1.6. ENCLOSURE AND DEGREE OF PROTECTION

Switchboards enclosures shall ensure in normal service (doors closed) a protection degree IP31according to IEC 60529, IP20 with door open or drawer in test or drawn-out position.

1.7. RATED VOLTAGES

1.7.1. Main voltage

This voltage is mentioned in the Site Specification, as well as the condition of the neutral point.The default value for a new plant with a frequency of 50 Hz is 400 V, three-phase.Unless otherwise mentioned, the neutral will be solidly earthed and not distributed.

1.7.2. Auxiliary voltages

These voltages are mentioned in the Site Specification. The default values for a new plant are :

230 V AC Normal for contactor coils and anti-condensation heaters.

230 V AC UPS for electronic modules and contactor coils when protection against feeder

voltage dips is required.

24 V DC for auxiliary relays and signalling lamps.

All these auxiliary voltages will be supplied by the ACC (out of this supply), as developed inSpecification STD.002.U13.

1.8. RATED INSULATING VOLTAGE

The insulation voltage for the busbars and power switchgear as well as for any circuit of theswitchboard shall not be less than:

Busbars: 1 000 V

Power switchgear: 690 V

Power circuits: 750V

Control switchgear and circuits: 500 V

1.9. RATED CURRENTS

The rating of the incoming circuit(s) shall be in accordance with the feeding transformer,

and at least equal to the total load of the users supplied, if the power of the feedingtransformer is not known.

The rating of the main busbar(s) shall not be less than this one of the incoming circuit(s).

Same rating shall be considered for the full length of each main busbar (no reduced crosssection at ends).


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Unless otherwise specified, every switchboard shall be designed for a continuous service.

1.10.SHORT CIRCUIT WITHSTAND STRENGTH

The rated short-time withstand current of the switchboard shall at least be equal to the short-

circuit current mentioned in the particular specification and shall in no case be less than50 kA rms during 1 s.

This shall also apply to the incoming circuit breaker, to bus-tie breakers and to outgoing

circuit breakers (please refer to section 3).

2. SWITCHBOARD CONSTRUCTION

2.1. COMMON REQUIREMENTS

2.1.1. General arrangement

The switchboard shall be defined with access to switchgear and to cables from the front

only. The switchboard shall be designed so that its sections (columns) can be installed eitherin one line or back to back (busbars shall be independent and segregated).

The main busbarshall be positioned on top or on the back of the switchboard and cables

shall enter from the bottom. If an incoming bus duct is used, this could enter from the top.

The switchboard shall be designed to be installed directly above the cable channel or on

technical floor without the addition of any part not supplied by the Supplier.

The switchboard shall be designed foreasy extension at least at one end.

All the switchboard components: busbars, outgoing feeders and its dimensions shall be

standardized as much as possible.

A minimum of 10% empty spare space shall be provided.

2.1.2. Switchboard structure

The switchboard shall be of modular and prefabricated type, assembled and equipped in

the factory. No section shall be higher than 2200 mm and access to each piece of equipment

and device shall be easy, especially for resetting thermal overload protection relays or formanoeuvring MCBs protecting auxiliary circuits.


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Anticorrosion protection of the metal structure (internal and external sides) shall be

ensured as follows:

Continuous hot dip galvanised sheet metal shall be used for non visible internal metal

parts. Visible metal parts shall be prepared by phosphatisation-cleaning treatment and

painted with either epoxy-polyester powder (minimum thickness 50 m) or acrylo-

urethane lacquer (minimum thickness 20 m). The finish shall be semi-gloss; the colour

will be the Manufacturers standard shade unless otherwise specified.

Ample passage shall be designed for the cables arriving from below, and supporting clamps

shall be available for fixing power and control cables. Cable channel width shall not be lessthan 300 mm.

Dust ingress and fire transmission will be stopped by closing these cable passages,after cables installation, with fire resisting materials (operation performed by the cabling

contractor).

Each switchboard section shall be equipped with a vertical copperearth collectorconnected

to an horizontal copper earth collecting bar. This shall terminate to an earthing tail,accessible when the board is alive and suitable for connecting a copper earthing cable. Thecross section of this earth collector shall be such that it will withstand the switchboards short-circuit current during 1 s, with a minimum cross section of 200 mm.

Switchboards shall be form 2 with doors open. At the minimum, Plexiglass (perspex)

screens will be provided in order to avoid contacts with live conductors (busbars and powerconnections).

Each access doorshall be locked by a single handle without key nor need of using any tool

as these switchboards will be installed in locked electrical rooms.

2.1.3. Incoming circuit(s)

The incoming section(s) shall be designed for connection to incoming feeder(s) either bybusbar provided with flexible connection or by cables.

2.1.4. Busbars

Main busbars (horizontal) and vertical busbars shall be ofelectrolytic coppertype Cu ETP

according to ISO 1337 standard.

Busbars which do not require maintenance shall be provided.

Metal sheets near high current busbars (1 600 A or more) shall be of aluminium or of other

non magnetic material.

All bolted connections shall be checked by using a torque wrench.


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2.1.5. Control and measuring circuits

Every control equipment shall be accessible from the front ofthe switchboard. Every signallingswitchgear and every indicator shall be visible from the front of the switchboard.

2.1.6. Remote Input/Output modules

Unless otherwise mentioned in the Site Specification, digital remote Input/Output modules

and their associated communication modules shall be installed by the Supplier on top ofeach switchboard section, in a compartment separate by a metal sheet from the portiondevoted to switchgears installation. Unless otherwise provided in the Site Specification,these I/O modules are not a part of this supply.

Every device of these modules shall be accessible directly from the front of the switchboard,

without having to remove any part.

Indication LEDs of I/O modules and of communication modules shall be perfectly visible to

a person standing in front of the switchboard, with its doors closed.

2.1.7. Wiring

The switchboard wiring shall be performed in accordance with the Lafarge standard

schematic diagrams included in section 12 of this document.

Terminal strips shall allow easy maintenance access to each wire terminal. They shall be

segregated between:

Power circuits

AC control circuits

DC control circuits.

Terminals:

Power terminals : screw type up to 16 mm core section, with a cable lug for largercables ;

Control terminals : shall be of insulation displacement type (needing no special tool forcompleting the connection) or of spring type.

Connectors with plug and sockets (several stages if necessary) shall be provided forcontrol terminals of plug-in modules.

Auxiliary voltages distribution to the different circuits will preferably be by adequate

prefabricated busbars. These busbars shall be adequately insulated to prevent anyaccidental contact.

Control wires shall be flexible, 500 V PVC insulated with a minimum core section of 1 mm.

Each wire shall be labelled or marked up at each end with the number of the terminal it isconnected to, according to manufacturers standard procedures. Wires shall be installed intrunkings of adequate sections.


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2.1.8. Labels

Following labels shall be provided and installed :

Switchboard main label installed at the upper left front part of the switchboard andindicating the tag (Lafarge code) and the description of the switchboard.

Switchboard indicating plate installed just under the main label and indicating :manufacturer, year, rated voltage, rated insulating voltage, incoming and main bus barrated currents, short circuit withstand current.

Section (column) number label installed on the upper middle front part of each sectionor of its door.

Module (plug-in type) or drawer (draw-out type) tag label to be secured to the fixed partfacing to corresponding module or drawer, indicating the tag (Lafarge code) and thedescription of the circuit.

Labels shall be engraved in black - cored white dilophane and fixed by screws or rivets (glue

not accepted). Letters height shall be at least :

15 mm for the switchboard main label

6 mm for the incoming, bus-tie and outgoing circuits labels

4 mm for the auxiliary circuits.

2.2. DRAW-OUT / FIXED TYPES

The Owner will specify whether the switchboard shall be of draw-out or plug-in type.

2.2.1. Draw-out type

The switchboard shall be form 3b (at least).

Each outgoing circuit shall be at least Service Index 333:

Operation: control circuits can be tested with the power circuit off

Maintenance: after switching it off, any outgoing circuit module can be removed andinserted without switching off the switchboard

Evolution: new outgoing circuits can be installed without switching off the switchboard.

Each drawer shall have 4 positions:

Connected (power and control on)

Test (power of, control on)

Disconnected (power and control off)

Removed.


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It shall be possible to lock out each drawer in disconnected position by up to 3 padlocks.

Power circuits shall be automatically disconnected in disconnected positions, as well on

upstream side than on downstream side.

Control circuits shall be disconnected in removed position either automatically ormanually by disconnecting a plug where pass all the control circuits through. Suchdisconnection/reconnection operation shall not need the use of any tool.

A contact from the drawer shall inform the PCS (and the operator) that this circuit is

unavailable when the drawer is in disconnected or removed position.

A defeater (mechanical interlocking system) shall be installed on each fixed part and on

each drawer to prevent from introducing a drawer of an inappropriate type or rating.

Signalling lamps and instruments (current and active power indicators) shall be installed in

front of drawers.

2.2.2. Fixed type

The switchboard shall be of modular type form 2b (at least), except sections housing

incomers and bus-tie breakers which shall be form 3b.

Each outgoing circuit shall be mounted and wired on an individual metal sheet plate, also

modular and standardized. It shall be possible to install or remove such modules fullyequipped without dismantling the adjacent modules or other cubicle parts or accessories.

Each outgoing circuit shall be at least Service Index IS 322, which means :

Operation : control circuits can be tested with the power circuit switched off.

Maintenance : after switching it off any outgoing circuit module can be removed withoutswitching off the switchboard.

Evolution : new outgoing circuits can be installed, if spare spaces exist, withoutswitching off the switchboard.

This plate shall support power connectors to be plugged in the busbar. It shall also support a

connector for connecting all the control circuits of the module. No connection with anotheroutgoing circuit or with switchboard common circuits shall be performed without passingthrough these plugs and connectors.

Each modular plate shall also support signalling lamps and instruments (current and

active power indicators). Alternatively, these items can be installed and wired to the front

door. If signalling lamps and instruments are mounted on the plates, each switchboardsection supporting outgoing circuits shall be equipped with a safety glass door with a rubberseal.


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3. POWER SWITCHGEAR

3.1. INCOMERS AND BUS-TIE BREAKERS

The incomers and bus-tie breakers shall have their protection devices co-ordinated with

the outgoing circuit breakers to guarantee a good selectivity. On feeders already protectedon upstream side (for instance by a circuit breaker connected to the secondary winding of thefeeding transformer) power switches (or circuit breakers without protection relays) shall beinstalled to avoid unnecessary selectivity steps.

Each circuit breaker or power switch shall be of draw-out type. It shall be equipped with a

system for locking out with 3 padlocks.

Each circuit breaker or power switch shall also have a closing auxiliary contact (normally

open) for initiating an alarm when in open position.

Emergency busbar (when applicable) shall be supplied in normal condition from the mainbusbar; in case of power failure from the emergency generator. Changeover shall be by2 circuit breakers or contactors mechanically interlocked to avoid paralleling these 2 sources.

If neutral is isolated, an insulation check metershall be installed on incoming circuit, with

an alarm contact open on low insulation resistance.

An emergency shut-down push button (red mushroom to be turned for unlatching) shall be

installed on the incoming section (column) of the switchboard and wired to switchboardsterminals.

3.2. OUTGOING CIRCUITS

Each outgoing circuit shall be protected by a circuit breaker from short circuits and

instantaneous overcurrents; fuses are not accepted. This circuit breaker shall be capable towithstand the full short circuit current. Its protection system shall be co-ordinated with cablescore section and cables length according to IEC rules (short-circuit condition, overloadcondition, voltage drop, installation conditions, protections against indirect contacts, ...).

Its handle shall provide forlocking it out with up to 3 padlocks.

Each outgoing circuit to a motor shall be protected by a thermal overload protection. Such

protection can be provided by a separate overload relay tripping the contactor coil. It can alsobe integrated in the above mentioned circuit breaker. If separate from the circuit breaker, it

shall also be co-ordinated according to IEC rules (overload condition).

For protecting motors driving large inertia equipment with long start-up time such as fans with

a power of 11 kW or more, heavy duty starters orelectronic soft starters shall be used.

Each motor shall be operated by a contactor (or two contactors for two directions motors

and two speeds motors).


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Each contactor shall be dimensioned for an AC-3 service according to IEC 60947-4 withfollowing derating: the contactor rated current shall be at least equal to :

150% of users rated current for motors up to 55 kW

130% of users rated current for larger motors.

Switchgear items of each outgoing circuit shall have a type 2 co-ordination according to

IEC standard, resulting in the absence of contacts welding and of damage on protectionsystem after any electrical failure.

The Supplier shall also check the compliance of equipment supplied with starting conditions

(magnetisation current, long starting time, )

Outgoing circuits shall be standardised in order to reduce quantities of spare parts to be

kept in the warehouse.

Protection functions (magnetic and thermal overload) and operating function can be grouped

in a combined equipment provided that the operated motor power does not exceed 22 kW. Considering all the switchboards included in the Supply, following spare outgoing circuits

shall be supplied (fully equipped) :

2 units for each rating of 1 direction motor feeder up to 15 kW

1 unit for each rating of:

- 1 direction motor feeder above 15 kW ;

- 2 directions motor feeder ;

- circuit breaker outgoing feeder.

The approval of the Owner shall be required on the choice of the switchboards where thesespare circuits will be installed.

4. CONTROL SWITCHGEAR AND MEASURING DEVICES

4.1. CONTROL CIRCUITS

On each incoming, bus-tie or outgoing circuit shall be installed two Miniature Circuit

Breakers :

1 MCB for protecting AC control circuits ;

1 MCB for protecting DC control circuits.

In case of a double busbar with a bus-tie, the three incoming/bus-tie circuit breakers/switches

shall have their trip coils interlocked to prevent any paralleling of sources.

The KA relay that controls the contactor kW shall be of safety relay type (IEC).


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A no-volt relay shall be installed in the incomer compartment; this relay equipped with a timer

(0 to 1 sec) shall cut off the contactors auxiliary voltage 230 VAC (recommended setting 0.5sec). The contact of this relay shall be connected in the series with the emergency shut-downcontacts.

In case of an emergency busbar an automatic switchover system shall be supplied to

change the sources in case of power failure and when the power is back. Auxiliary contactsof the switchboard system shall be wired to switchboards terminals in order to inform thePCS.

Each outgoing circuit shall be equipped with signalling lamps indicating :

Green:

- running direction 1 / speed 1

- running direction 2 / speed 2 (if applicable)

Yellow: Circuit available (drawer in operation position, power switch and/or circuitbreaker closed, thermal overload protection in normal position, auxiliary voltages MCBs

closed)

Red: Trip (circuit breaker and thermal relay).

These lamps shall use Light Emitting Diodes (bulbs with a filament are not accepted).Lamp colours are shown on Lafarge standard schematic diagrams (please refer to section12).

Unless otherwise mentioned in the Site Specification, each control circuit (and each alarm

circuit) shall be connected to Remote Digital Input/Output modules to be installed on top of

each switchboard section (column) in a closed compartment isolated by a metal sheet fromthe rest of the section. These modules will communicate with the PCS. Unless otherwisementioned, the supply of these RI/O modules and their associated devices (power supply,connectors, ...) is not included in this scope of work. This in order to minimise site cablingand be able to perform a maximum of tests at the workshop.

Alternatively, for incoming circuits, the metering units mentioned in section 4.2 can beused for the transmission of their control signals to the plant control system.

When required by the Site Specification, the switchboard shall be intelligent. Each incoming

and each outgoing circuit shall be controlled by a fieldbus connected to the PCS. It shall bepossible to modify the parameters of these circuits through this fieldbus.

Each outgoing circuit shall be wired up in accordance with the Lafarge standard schematic

diagrams under section 12. Inter allia, terminals shall be supplied for connecting local STARTand STOP commands from the VCS supplied by others.

4.2. PROTECTIONS

Following alarms shall be made available to the PCS :

Incoming/bus-tie breaker is in off position (please refer to section 3.1);


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MCB protecting AC control circuits is in off position (please refer to section 4.1);

MCB protecting DC control circuits is in off position (please refer to section 4.1);

Insulation resistance too low if an insulation checkmeter is installed at the incoming feeder

(please refer to section 3.1).

The emergency shut-down push-button installed on incoming section (please refer to section 3.1)will trip the MV circuit breaker feeding the transformer supplying this switchboard (cabling to beperformed by the cabling contractor).

4.3. MEASURING DEVICES

Every current transformershall have a secondary winding rated for 1 A, and shall withstand

the maximum possible short circuit current.

An electrical parameters metering unit shall be installed on each incoming circuit. Thisshall measure at least following parameters : 3U, 3V, 3I, P, Q, S, f and PF and display theseparameters (according to operator selection).This unit shall also meter active and reactive energies and provide a pulse output for activeenergy.

This metering unit shall also monitor the presence of the three phases and send analarm through the fieldbus (see below) in the absence of one or several phases, or in case offailure of this device.It shall include communication with the PCS by a fieldbus PROFIBUS DP. On this fieldbusshall be made available all above measurements and alarms.

Every outgoing circuit supplying a motor with a power of 30 kW or more or a material

handling equipment (screw conveyor, bucket elevator, chain conveyor, belt conveyor, ) ofany power shall be equipped with a current transducer converting the full motor currentrange in a 4-20 mA DC signal connected to the plant control system through outgoingterminals and to a current indicatorinstalled on the drawer front/plate or adjacent to it.

The current transducer and the current indicator shall be replaced by an active power

transducerand an active power indicatorfor bucket elevators and for cooler drag chains.

5. PCC/MCC SUPPLYING VSDS

These LV boards shall be provided with two motorised incoming circuit breakers supplying

two separate 3-phase busbars (please refer to the diagram indicated in section 12). Theirsimultaneously switching-on and switching-off shall be ensured by a dedicated control circuit.

Each 3-phase incoming feeder shall be provided with following protections :

A surge protection on each phase

An insulation check meter

The outgoing circuits supplying VSDs shall be equipped with fast fuses.


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The loads of each bus barshall be balanced as far as possible. A single line diagram of the

switchboard shall be submitted to the Owners approval.

6. POWER FACTOR CORRECTION UNITS Unless otherwise specified, a power factor correction unit shall be supplied with each set of

PCC/MCC. The reactive power of this unit shall be calculated so to increase the power factorof the switchboard from natural value (typically 0.7) up to 0.92 unless more stringentrequirements from the Site Specification.

Following table indicates the minimum rated power required for power factor correction units

according to the transformer rated power supplying this set of PCC / MCC:

Feeding transformer ratedpower(kVA)

Power factor correctionunit rated power required

(kVAR)

630 275

1000 425

1250 520

1600 675

2000 850

2500 1050

This power factor correction unit shall be of automatic type, connecting or disconnecting thecapacitor banks by steps according to power factor fluctuations. Steps shall not exceed50 kVAR each. All the capacitor banks shall be identical.

It shall be housed in a separate cabinet to be installed either at the end of the PCC or MCC

or behind their incoming section. This cabinets look shall match as much as possible withthe PCC or MCC.

It shall be connected to corresponding PCC or MCC by an outgoing circuit breaker of

appropriate rating.

It shall be designed in order to be remotely turned on and off.

The protection against harmonic currents will be considered taking into account the ratio kbetween the power of harmonics generated and the power of the transformer feeding thePCC/MCC :

k < = 15% : no harmonic protection required

k > 15% and < = 25% : reinforced type is required

k > 25% and < = 50% : anti-harmonic inductances are required


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k > 50% : anti-harmonic filters are required

The type of protection against harmonic currents shall be submitted to the Owners approval.


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The protection fuses shall be provided with a trigger , with trip local signalisation and one

NC contact for remote alarm.

Each unit shall be equipped with discharge resistors for operators safety.

Note: For new department electrical distribution, at least, reinforced type is required.

7. DOCUMENTS

7.1. DOCUMENTS TO BE SUPPLIED BY THE OWNER

Site Specification which details site conditions, voltages,

Particular Specification : this document, complemented with a single line diagram if

required, shall specify, when not mentioned in the Site Specification :

draw-out or plug-in type

sections arrangement back-to-back or in one row

incoming (stand-by) rated currents

short circuit current to be considered for each board

emergency busbar rated current (if applicable)

power factor correction unit rated power required or power factor to be achieved withall the users in operation.

Consumers List specifying for each user : rated power

rated current

rated voltage

type of circuit (with/without contactor, one way/two ways, normal/heavy start)

accessories (current/active power transducer and indicator)

power cable core section (the Supplier to mention when it needs this document).

7.2. DOCUMENTS TO BE PREPARED BY THE SUPPLIER

Following documents shall be prepared in English (unless otherwise stated in the SiteSpecification) in accordance with the requirements of specification STD.002.U02.

Single Line Diagram giving references of upstream equipment : feeders tag numbers,

upstream single line diagrams, ...

Selectivity Study demonstrating that protections are effective and co-ordinated.


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Lay-Out of each switchboard with dimensions and position of each circuit.

Lay-Out of each module(Typical)

Civil Works Guide Drawing for each switchboard.

Typical Detailed Schematic Diagrams for each circuit type (including auxiliary circuits).

These diagrams shall also mention the number of every terminal.

Interlocking Diagrams if applicable.

Equipment list of Switchgear installed with technical details.

Application software of each programmable equipment.

Interface tables of exchange (addresses clearly indicated) of each programmable

equipment.

Manufacturing Time Schedule.

Installation and Maintenance leaflets.

Recommended Spare Parts Lists :

for commissioning

for 2 years operation.

7.3. DOCUMENTS TO BE SUBMITTED WITH THE OFFER

Following documents shall be submitted in English with bid:

Detailed specification of the proposed equipment

Technical characteristics of each switchboard

Front face and dimensions of each switchboard

Type tests certificates according IEC 60439-1 for:

Icc 50 kA 1s

Ingress protection certificate.

8. FACTORY TESTS

The Supplier shall notify the Owner not less than 14 days prior to the testing period, in order thatthe Owner may, should he think it necessary, delegate a representative to witness these tests.

Following tests shall be performed on each switchboard, according to IEC 60439-1 standard,completely assembled except main busbars connections between sections which are to beseparately packed for despatch and a detailed test procedure be submitted to the Owner priorstarting the tests.


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Measuring insulation resistances (power and control circuits)

Dielectric tests (power and control circuits)

Operation tests

Check of interlockings and safety devices

Check of drawers interchangeability (if applicable)

Check of dimensions and accessories.

The Supplier shall also supply copies of type test reports proving the short circuit withstand of theswitchboard.

All these factory tests/type tests will be performed at the Supplier's expenses.A detailed test report shall be prepared by the Supplier and handed over to the Ownersrepresentative or mailed to the Owner if it has not witnessed the tests.

9. GUARANTEE

Minimum required guarantee is 24 months after commissioning, with a maximum of 30 monthsafter the switchboards are ready for factory tests.

10. DATA SHEETS


DocumentSTD.002.U07

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Rev.A


20/33

CUSTOMER: SUPPLIER :PROJECT:

DATA SHEET PROJECT No:POWER CONTROL CENTRE, MOTORCONTROL CENTRE

OFFER:

EQUIPMENT: DATE :

Type

1

Draw-out/Plug-in

2 Protection degree IP

3 Segregation Form

4 Service index ISManufacturer

5 Cabinets

6 Switchgear

Service conditions

7

Rated voltage V

8

Insulation voltage V

9 Short-time withstand current kA

Incoming circuit

10

Rated current of main circuit breaker A

11 Short circuit current of main circuit breaker kA12 Feeder by busbar/cables

13 Measurement device14 Insulation checkmeter (if applicable)

Busbars15 Main busbars (horizontal) rated current A

16 Material / cross section17 Secondary busbars (vertical) rated current A

18 Material / cross section19 Maintenance required

Control


DocumentSTD.002.U07

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20 Remote I/O modules / intelligent switchboard

Accessories

21 Anti-condensation heaters required Yes/No22 Others Yes/No

Dimensions23 Switchboard height mm24 Switchboard depth mm

25 Switchboard length mm26 Cable channel width mm

Painting27 Preparation

28 Finish

29 Deviations from this specification

CUSTOMER: SUPPLIER :PROJECT:

DATA SHEET PROJECT No:LV POWER FACTOR CORRECTION UNIT OFFER:

EQUIPMENT: DATE :

1 Type

2 Manufacturer

3 Rated voltage V

4 Insulation voltage V

5 Total capacity kVAr

6 Capacity of each step kVArPower factor regulation V

7 Regulation load relays in each unit Yes/No8 Remote turn on and off Yes/No

Protection against harmonic currents9 Reinforced protection Yes/No10 Anti-harmonic inductance Yes/No

11 Anti-harmonic filters Yes/No

Dimensions12 Cabinet height mm13 Cabinet depth mm

14 Cabinet length mmPainting

15 Preparation

16

Finish

17 Deviations from this specification


DocumentSTD.002.U07

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Notes:

1. Values to be mentioned in boxes marked with sign are to be given by the Owner or bythe main Contractor.

2. The Supplier is requested to fill in a data sheet for each type of equipment proposed andto return it with its proposal.

11. SWITCHGEAR SELECTION TABLES

11.1.SWITCHGEAR SELECTION FOR 400 V MOTORS USING LINE STARTERS

P (kW)Current

(A)Contactor Thermal C-breaker* CT Ratio

0.25 0.8 25 0.63 to 10.37 1.1 25 1.00 to 1.6

0.55 1.6 25 1.00 to 1.6

0.75 2 25 1.60 to 2.5

1.1 2.5 25 1.60 to 2.5

1.5 3.3 25 2.50 to 4.0

2.2 4.6 25 4.00 to 6.0

3 6.0 25 4.00 to 6.0

4 8.4 25 7.00 to 10

5.5 11 25 10.0 to 13

7.5 15 25 13.0 to 18

11 20 40 18.0 to 25 15 28 40 23.0 to 32

18.5 34 63 30.0 to 40

22 40 63 38.0 to 50

25 47 80 0.63 to 1 50/1

30 55 80 " 60/1

37 66 115 " 100/1

55 100 185 " 125/1


DocumentSTD.002.U07

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23/33

75 128 185 " 150/1

90 156 265 " 200/1

110 205 265 " 250/1

132 224 400 " 250/1

160 280 400 " 300/1200 349 400 400/1

250 434 630 630/1

Up to 63 A, circuit breakers are equipped with thermal overload and magnetic protection circuitsrated for standard motors.

* to be filled by MCC Supplier for type 2 co-ordination (please refer to section 7.2). Thenumber of circuit breaker sizes will be limited to reduce spare part stock.


DocumentSTD.002.U07

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11.2.SWITCHGEAR SELECTION FOR 500 V MOTORS USING LINE STARTERS

P (kW) Current(A)

contactor Thermal C-breaker* CT ratio

0,25 0,8 25 0,63 to 1

0,37 1,1 25 1,00 to 1,6

0,55 1,6 25 1,00 to 1,6

0,75 2 25 1,60 to 2,5

1,1 2,5 25 1,60 to 2,5

1,5 3,3 25 2,50 to 4

2,2 4,6 25 4,00 to 6

3 6 25 4,00 to 6

4 8,4 25 7,00 to 10

5,5 11 25 10,00 to 137,5 15 25 13,00 to 18

11 20 40 18,00 to 25

15 28 40 23,00 to 32

18,5 34 63 30,00 to 40

22 40 63 38,00 to 50

25 47 80 0,63 to 1 50/1

30 55 80 " 60/1

37 66 115 " 80/1

45 80 185 " 100/1

55 100 185 " 125/1

75 128 185 " 150/190 156 265 " 200/1

132 224 400 " 250/1

160 280 400 " 300/1

Up to 63 A, circuit breakers are equipped with thermal overload and magnetic protection circuitsrated for standard motors.

* to be filled by MCC Supplier for type 2 co-ordination (please refer to section 7.2). Thenumber of circuit breaker sizes will be limited to reduce spare part stock.

12. DIAGRAMS


DocumentSTD.002.U07

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Rev.A


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MCC single line diagrams in 2 versions :

Either the emergency generator feeds the essential users through the normal busbar ofthe MCC and the load shedding of the other users is controlled by the PCS.

Or the MCC is equipped with an emergency busbar for feeding the essential usersfrom the emergency generator, the other users being connected to the normal busbarnot fed from the emergency generator.

Lafarge standard schematic diagrams of 5 types :

K1 : motor one direction

K2 : motor two directions

KM : actuator 2 positions

VS : variable speed drive (VSD installed inside the MCC)

Q : circuit breaker supplying a package such as a crane panel,

For each schematic diagram following facilities shall be specified by following suffixes:

E : emergency shut-down (pull-rope, push-button)

I : current measurement

J : power measurement

S : speed monitor

H : heavy start.

Examples :

Belt conveyor : K1 EIS

Fan, Pmot > 30 kW, direct start : K1 IH

Kiln motor : VS I


DocumentSTD.002.U07

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MOTORCONTROLCENTRE

TypicalsinglelinediagramwithoutLVemergencysupply

I

PE

MODULE(KY)

MEASURING

3

By-Pass

CONSUMERS

FEEDINGESSENTIAL

230Vac

400V

Auxiliary

Transformer 2

30Vac

UPS(UP)

STEPREGULATIONACCORDINGTOPF&LOAD

CAPACITORBANK

MOTORSTARTERMODULES

MEDIUM/LOW

VOLTAGE

DISTRIBUTIONTRANSFORMER(TF)

PACKAGE

(TF)

MainHorizontalBusbars

NOTDISTRIBUTED

NEUTRALCONDUCTOR

TN-SNETWORK

INCOMINGFEEDER

I

I

I

I

I

I

I

I


DocumentSTD.002.U07

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Rev.A


27/33

V

G3

EMERGENCY

GENERATOR

Emergency

HorizontalBusbars

I

I

I

I

I

I

I

I

MOTORCONTROLCENTRE

TypicalsinglelinediagramwithLVemergencysupply

I

PE

MODULE(KY)

MEASURING

3

By-Pass

CONSUMERS

FEEDINGESSENTIAL

230Vac

400V

Auxiliary

Transform

er

2

30Vac

UPS(UP)

STEPREGULATION

ACCORDINGTOPF&LOAD

CAPACITORBANK

MOTORSTARTERMODULES

NOTDISTRIBUTED

NEUTRALCONDUCTOR

TN-SNETWORK

MEDIUM/LOWV

OLTAGE

DISTRIBUTIONTRANSFORMER(TF)

PACKAGE

(TF)

MainHorizontalBusbars

INCOMINGFEEDER

PE

3


DocumentSTD.002.U07

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Rev.A


28/33

Fastfuses

M

M

M

M

M

M

M

M

M

M

M

M

M

M

M

3

3

IM

Surgearrester

3

3

1000A

1000A

MV/LV

transformer

MOTORCONTROLCENTRE

MCC316MC13-V

SDKilnDownstream(example)

318HE01MT21

318HE01MT18

318HE01MT15

318HE01MT12

IM-I

nsulationMonitoring

Note:fastfusesforVSDprotection

110kW

317FA07MT10

IM

3*30kW

318HE01MT19

318HE01MT20

Busbar1

Busbar2

3*30kW

3*30kW

3*30kW

132kW

75kW

75kW

316AB13MT10

318HE01MT10

318HE01MT13

318HE01MT16

318HE01MT11

318HE01MT14

318HE01MT17

317FA05MT10

317FA03MT10

400V

M


DocumentSTD.002.U07

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29/33

MOTORCONTROLCENTRE

Typicalschematicdiagram-Motor1direction-K1type

DrawerorPla

te

I/OCompartment

MarshallingBoard

Othermachinesensors

MotorCurrentorPower

XXnn

YI

Digitalinput

Analogueinput

Speedswitch

XS

2

4Vdc

S

Speedmonitor

230Vac

-Q1

-KB

400V

-KM1

-F1

/

3M

Cable-Loop

Field

VisibleCut-offSwitch

-KM1

-KA1

Heavystart(ifany)

H I J

Currentmeasureor

Powermeasure

3Padlocks

ToQ1Trip

+24Vdc

0V

-KA1

-KB

-KM1

-F1

Yellow

Green

Red

HS

L1

LS

E

EmergencyShut-Down

1

3

44

3

1

8

7

Pre-Cutoff

LocalStart

Availability

Feedback

B1

AV

L1

Digitaloutput

Digitalinput

LS

EmergencyShut-Down

HS

LocalStop

MotorOperatingMode:

ChoiceofSequential/Localmodeismadebyoperator

ontheOperatorStation

StartCommand

C1

2

-Q1

Trip

2

pullrope

-Q11

-Q12

Precut-off

Available

Running

Failure

3 247110

12

(ifapplicable)

1

3

4

7

4

3

1

2

3 247110

12


DocumentSTD.002.U07

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Rev.A


30/33

LocalStop

MotorOperatingMode:



S

Speedmonitor

Heavystart(ifany)

H I J

Currentmeasureor

Powermeasure

E

EmergencyShut-Down

1

4

55

4

1

10

11

10

11

3 2

3

2

8

7

3Padlocks

Pre-Cutoff

ToQ1Trip

0V

-Q11

-Q12

Precut-off

Available

Running

Direction1

Failure

pullrope

23 541

1

1

0

RunningDirection2

1

3

1

2 1 87

(ifapplicable)

1

4

5

10

11

3 2

7

-KM1

-KA1

-KM2

MOTORCONTROLCENTRE

Typicalschematicdiagram-Motor2directions-K2type

230Vac

-Q1

-KM2

-KB

400V

-KA2

-KM1

-F1

/

+24Vdc

-KA2

-KB

-KM1

-F1

-Q1

Trip

Yellow

Green

Red

DrawerorPlate

I/O

Compartment

StartCommandDirection1

LocalStartDirection1

Availability

FeedbackDirection1

LocalStartDirection2

B1

AVC

1L1

L2

3M

Cable-Loop

HS

Digitaloutput

Digitalinput

MarshallingBoard

Othermachinesensors

MotorCurrentorPower

XXnn

YI

Digitalinput

Analogueinput

Field


Speedswitch

XS

-KM1

-KM2

-KM2

Green

FeedbackDirection2

B2

LS

-KA1


C2

Emergency

Shut-Down

HS

L1

L2

LS

24Vdc


DocumentSTD.002.U07

Page30/33

Rev.A


31/33

MOTORCONTROLCENTRE

Typicalschematicdiagram-Actuator2positions-KMtype

230Vac

-Q1

400V

-F1

+24Vdc

-KA2

-KB

-KM1

-F1

-Q1

Trip

Yellow

Green

Red

DrawerorPlate

I/O

Compartment


(open)

LocalStartDirection1(open)

Availability

LocalStartDirection2(close)

AVC

1L1

L2

-KM2

Precut-off

1

3

1

2

1

47 8115

4

5

10

119 3

8

71

-KM2

-KB

-KA2

-KM1-

KM1

-KA1

-KM2

3M

Cable-Loop

Digitaloutput

Digitalinput

MarshallingBoard

Othermachinesensors

XXnn

Digitalinput

Analoginput

Field


-KM2

Green

LS

XZ20

XZ10

-KA1


(close)

C2

XX10

L1

L2

LS

24Vdc

XZ10

Position1

XZ20

Position2

Torque

switch

Position1switch(open)

Torqueswitch(ifany)

LocalStop

Position2switch(close)

MotorOperatingMode:



1

4

55

4

1

10

11

9

10

119 3

3

8

7

Actuator

3Padlocks

Pre-Cutoff

ToQ1Trip

0V

Analogueoutput

Positionsetpoint

ZC

PositionFeedback

YZ10

FeedbackDirection1

B1

FeedbackDirection2

B2

34

591

1

1

0

Available

Running

Direction1

Failure

RunningDirection2

-KM1


DocumentSTD.002.U07

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32/33

LocalStart

Availability

Feedback

B1

AV

L1

Digitaloutput

Digitalinput

LS

Emergency

Shut-Down

HS

LocalStop

MotorOperatingMode:



StartCommand

C1

2

-Q1

Trip

2

-KA1

-C1

Speedfeedback

YS

Speedset-point

SC

ToVSD

insideMCC

LU

LocalSpeed-up

LD

LocalSpeed-down

LU

161

6 LD

66

FieldbustoPCScontroller

230VUPS

-Q11

-Q13

-Q12

-KM1

Available

Running

Failure

Precut-off

pullrope

261641

0

Note:fastfusesforVSDprotection

31 712

MOTORCONTROLCENTRE

Typicalschematicdiagram-Motorspeedvariation-VStype

DrawerorPlate

I/OCompartment

MarshallingBoard

MotorCurrentorPower

YI

Analoginput

Analogueoutput

230Vac

-Q1

-KB

400V

-F1 3

M

Cable-Loop

Field


-KM1

-KA1

3Padlocks

ToQ1Trip

+24Vd

c0V

-KA1

-KB

-KM1

-F1

Yellow

Green

Red

HS

L1

LS

E

EmergencyShut-Down

1

3

44

3

1

8

7

Pre-Cutoff

(ifapplicable)


DocumentSTD.002.U07

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Rev.A


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MOTORCONTROLCENTRE

Typicalschematicdiagram-Packagecircuitbreaker-Qtype D

rawerorPlate

I/OCompartment

M

arshallingBoard

CurrentorPower

YI

Analogueinput

Q1

400Vac

/

Field


I J

Currentmeasureor

Powermeasure

3Padlocks

Availability

AV

Digitalinput

PACKAGE

2

4Vdc

Documents

Electrical Standarts