DC UPS

OPERATION & MAINTENANCE DOCUMENTATION GT 11 DC & UPS SYSTEM Owner’s Consultants Owner ESB International PETRO VIETNAM PECC2 Employer’s Consultant Employer VIETNAM MACHINERY ERECTION CORPORATION - Power Island Contractor ALSTOM (Switzerland) Ltd Project NHON TRACH CCPP, VIETNAM ALSTOM-Doc.-Nr NHT/11/G/BR_BT -/MM/070 We reserve all rights in this document and in the information contained therein Reproduction, use or disclosure to third parties without express authority is strictly forbidden © STATRON 2003 Statron AG · Industrie Nord · CH-5506 Mägenwil · TEL ++41 62 887 887 · FAX ++41 62 887 888 · statron@statron.com Rev Description Date Issued Checked Approved Page / of Emission 17.07.2007 J.Hunger E.Bieri J.Hunger 1/2 M311540-11-2 (1) Chap Document Nr Description M640004-E Erection, Assembly, Shipping and Handling Instructions Single line & Layout of Equipment A311540-010 NHT/00/G/BR_BT -/WD/101 M311540-01-1 Cable List DC&UPS System M311540-21 C69BA2F0001AA000 00-307439 7140203191_install 7140203051_commiss 7140203021_operating GroE_en0107 Battery Sizing Data Battery Rack Drawing Battery Wiring Diagram Battery Installation-Manual Battery Commissioning-Manual Battery Operating-Manual Battery Data Sheet S311540-110 NHT/11/G/BT /WD/102 S311540-111 NHT/11/G/BT /WD/103 Set of Drawings & Partslist (BTL10 ) S311540-120 NHT/11/G/BR /WD/102 S311540-121 NHT/11/G/BR /WD/103 Set of Drawings & Partslist (BRU10, BRA10/20) S311540-130 NHT/11/G/BT /WD/105 S311540-131 NHT/11/G/BT /WD/106 S311540-132 NHT/11/G/BT /WD/107 Set of Drawings & Partslist (BUA10) Set of Drawings & Partslist (BTM10 ) (Dimensions/Layout/Terminal list/Wiring Diagrams) Set of Drawings & Partslist (BRU20, BRB10/20) Set of Drawings & Partslist (BUB10) Set of Drawings & Partslist (BUC10/20) (Dimensions/Layout/Terminal list/Wiring Diagrams) T311540-100 NHT/11/G/BR_BT -/EM/090 Factory Routine Test Reports M311540-11 System Description M621005E Battery Charger O&M M311540-13 Technical Data Battery Charger M653006E UPS / Inverter O&M M311540-16 Technical Data UPS / Inverter M311540-17 220V DC Distribution O&M 10 page (2) M311540-11-2 STATRON AG, Switzerland Describtion: Type DC & UPS Revision: B Doc.-type: Prepared: Checked: Approved: J.Hunger H.Würsch J.Hunger Valid for: File no.: MANUAL Replaces: IS2 Cabinets M640004-E Language: Page: E Order-nbr.: general 1/13 Data set: 02.05.2007 ERECTION, ASSEMBLY, SHIPPING & HANDLING INSTRUCTIONS for DC and UPS System (in IS2 cabinets) Q:\MANUALS\Allgemein\640004\M640004-E.doc We reserve all rights in this document and in the information contained therein Reproduction, use or disclosure to third parties without express authority is strictly forbidden  STATRON 2007 Statron AG · Industrie Nord · CH-5506 Mägenwil · TEL ++41 62 887 887 · FAX ++41 62 887 888 (3) Page: 2/13 This side intentionally left blank (4) File no.: M640004-E Page: 3/13 File no.: M640004-E Table of Contents HANDLING 1.1 1.2 1.3 ERECTION 2.1 2.2 2.3 2.3.1 2.4 2.5 EQUIPMENT DESCRIPTION INTERMEDIATE STORAGE TRANSPORT CHECKS ON DELIVERY CONSTRUCTIONAL REQUIREMENTS .7 ERECTION AND CONNECTION OF THE CUBICLES Additional informations for switchgear positioning FASTENING METHODS TO FOUNDATION .9 DRIP PROTECTION ROOF (OPTIONAL) 12 CABLE CONNECTIONS, WIRING .13 (5) Page: File no.: 4/13 M640004-E HANDLING 1.1 Equipment Description General The critical source panels, i.e chargers, inverters and distribution boards are built-up of single cabinets in fixed technique The basic elements of the frames are Csections of 2mm thick sheet steel with holes at 25mm intervals The parts of the frame are secured with threadforming screws and require no maintenance The single cabinets are separated by separation walls The cabinets are equipped with rear plates, hinged front doors and end plates 1.2 Intermediate Storage The nature and duration of intermediate storage are dependent on the type of packaging Cubicles in standard packaging Cubicles with export/ seaworthy packaging Store indoors after arrival where no condensation can occur Unpack immediately Open the doors for several hours to acclimatize the equipment Cover the cubicles with plastic sheeting for any subsequent storage periods Check regularly for condensation forming under the sheeting until the start of installation • Moisture protection is only guaranteed if the packaging is undamaged • Possibility of intermediate storage outdoors • Storage period of maximum 12 months if wrapped in heat sealed PE sheeting and the packaging is undamaged • When the storage period is exceeded, the drying agent must be replaced and the plastic sheeting has to be resealed If condensation occured don't commission the unit until it is completely dry Open the doors for several hours to acclimatize the unit or run the cubicle heaters for 2-3 days (6) Page: File no.: 5/13 1.3 M640004-E Transport The unpacked cabinets can be transported by crane or fork-lift snuck By fork-lift truck Switchgear cubicles have to be transported only in the vertical position Tilting and canting must be avoided Cubicles may easily tip over when transported with a hand-pulled truck Therefore the distance between the wooden cross beam or the pallet and the underground should not be more than mm (7) Page: 6/13 By crane (8) File no.: M640004-E Page: 7/13 File no.: M640004-E ERECTION 2.1 Checks on delivery Check the consignment on arrival at site for: • • • • Completeness transport damage (if found, determine extent, cause and originator) When damage is detected it must be proceeded as follows: Immediately write down visible damage in the consignment note Report hidden damage in writing to the relevant forwarding agent within one week When certification is missing or a claim has not been made, the manufacturer can disclaim all liability 2.2 Constructional requirements To prevent damage being caused by moisture and dirt the following tasks (only examples) must be carried out before erection of the switchgear: • • • • • Walls and ceilings DRY, painting completed Doors and windows installed Openings in the floor, wall and ceiling for cables, conductors pipes, bars and ventilation in accordance with the construction drawings provided Supporting brackets, beams, enclosures and foundation frames assembled and painted If necessary, assemble braces appropriate to the basic dimensions of the switchgear installation with cross struts corresponding to the cubicle divisions Suitable indoor conditions must be maintained Adequate lighting as well as free access to the switchgear rooms must be provided Excessive temperature fluctuations together with high humidity should be prevented by heating the room Condensation should also be prevented (9) Page: 8/13 File no.: M640004-E 2.3 Erection and connection of the cubicles The erection of the cubicles should be carried out, as described the following: The shipping units which are to be erected in one row have to be aligned accurately and checked that they are vertical Doors and panels must not be twisted or stressed The erection can start at the left or at the right The frames of the shipping units have to be screwed together The vertical sections are already fitted on the front and rear with special nuts Note: for protection class IP5x and higher or IPx1 and higher the rubber seal has to be be attached between the frames Additionally to the vertical sections or if the access to the joints in the vertical sections is obstructed, the bottom sections can be screwed together using the frame connectors which are enclosed (10) DC DISTRIBUTION H33(A4) JOP2 FAILURE (JACKING OIL PUMP 2) A Is cb +DB002-Q1 off? Yes: • The motor of the Jacking oil pump may be overloaded or blocked or the wiring is defect Close cb +DB002-Q1 Does it trip again? Yes: Disconnect load on terminals +HB002-X3/L+1 and L+2 No: No: B If the cb still trips check internal wiring according wiring diagram or change cb +DB002-Q1 End Proceed with B Is mcb +DB002-F2 off? Yes: • The mcb itself, or one of the contactors and relays in +DB002 may be defect Check the circuit according wiring diagram No: M311540-17 (376) • Check the circuit according wiring diagram The aux contacts of +DB002-Q1 or +DB002-F2 may be defect page 14 DC DISTRIBUTION H34 A ELOP FAILURE (EMERGENCY LUBE OIL PUMP) Is mcb +FA-F02 off? Yes: The mcb itself or one of the contactors or relays +FA-K10, -K11, -K12, -K13, -K23, -K41, K42 may be defect Check the circuit according wiring diagram No: B Proceed with B Is mcb +FA-F03 off? Yes: The mcb itself or one of the contactors or relays +FA-K01, -K02, -K03, -K52 may be defect Check the circuit according wiring diagram above No: C Proceed with C Is cb +FA-Q01 off? Yes: If the handle is in the mid position, the circuit breaker tripped due to a short circuit in the ELOP or the cable to the ELOP (Note: -Q01 has magnetic trip only and no thermal trip) If the handle is down in the OFF position, the c.b was switched off manually No: Proceed with D page 15 M311540-17 (377) DC DISTRIBUTION D Is 230VAC voltage on terminals +HB003-X1/7-8 ok? M311540-17 (378) Yes: One of the relays +FA-K01, -K23, -K42 or the aux contact of -Q01 may be defect No: Check feeder voltage of inverter BRU10/BRA10 on cable feeder “AUX VOLTAGE ELOP” in BRA10 page 16 DC DISTRIBUTION OPERATING INSTRUCTIONS (Providing the commissioning is done according „COMMISSIONING” chapter 4, and no changes have taken place such as rewiring and so on.) 3.1 Condition Switching on from de-energised state All distribution boards are considered to be completely voltage free and m.c.b’s, switches and fuses are OFF CAUTION! Some of the distribution boards includes remote controlled circuits operated with external control voltages Even with all input feeders open and mcb’s switched off there may be voltage present in the cabinets CAUTION! Before switching on the power to the distribution boards carefully check that all connected consumer are ready to be supplied with power It is recommended to open all output mcb’s before distributions are supplied with power If works are in progress on some consumers the relevant feeder mcb in the distribution board must be padlocked page 17 M311540-17 (379) DC DISTRIBUTION BUA, BUB (1) Close input feeder BUA10GS100 in BUA resp BUB10GS100 in BUB The voltmeter P1 now shows the busbar voltage The LED H21/22 “HIGH/LOW DC VOLTAGE” shall go OFF (2) Close feeder circuit breaker BUC10GS101 in BUA resp BUC10GS102 in BUB (3) Before closing the remaining CF mcb’s -F1 verify that the relevant consumer are ready When all mcb’s are closed the LED H23 “MCB OPEN” shall go OFF M311540-17 (380) page 18 DC DISTRIBUTION BUC10/20 (4) The LED H11/12 “HIGH/LOW DC VOLTAGE” shall be OFF Power Oil Pump Rotor Barring (5) Close feeder mcb +CB-F2 and the mcb +CBQ1 for the Power Oil Pump Barring The LED H31 “ROBA FAILURE” shall go off CAUTION! This output is now remote controlled Jacking Oil Pump (6) Close feeder mcb +DB001-F2 and the mcb +DB001-Q1 for the Jacking Oil Pump The LED H32/A4 “JOP FAILURE” shall go off CAUTION! This output is now remote controlled Jacking Oil Pump (7) Close feeder mcb +DB002-F2 and the mcb +DB002-Q1 for the Jacking Oil Pump The LED H33/A4 “JOP FAILURE” shall go off CAUTION! This output is now remote controlled page 19 M311540-17 (381) DC DISTRIBUTION Emergency Lube Oil Pump (8) Close mcb +FA-F02 and +FA-F03 of the Emergency Lube Oil Pump (9) Turn key switch +FA-S01 to “INITIALIZE” position, check that the bar mounted contactor +FAK03 is activated, the LED H24(A4) “ELOP OFF” shall light up, if not there may be a continuouse ON command from the remote control side (relay +FA-K22 or +FA-K32 is ON) or +FA-K52 is not on (monitoring of main lube oil pump), if so - stop the procedure and solve the external problem first or set the remanence relay +FA-K44 to “not active” (10) Close the maintenance breaker +FA-Q01 (11) Set the remanence relay +FA-K44 to “PS ACTIVE” (depending on status of turbine) The LED H34(A4) “ELOP FAILURE” shall go off CAUTION! This output is now remote controlled BUC20 (11) Close feeder switch AB003-Q1 (BUC20GS101) (12) Before closing the remaining load mcb`s -F1 verify that the relevant consumer are ready When alle mcb`s are closed the LED H31(A3) “MCB OPEN” shall go off M311540-17 (382) page 20 DC DISTRIBUTION COMMISSIONING Before feeding the distribution boards for the first time after installation with power, the following checks of the power connections and control electronics must be carried out carefully 4.1 Connections This check must be made before any DC voltage is applied to the distribution! Based on the terminal list (see Part 2, chapter 2-4) carefully check that the connections on the input side and on the load side are correct and make sure that each connection wire or cable is tightly connected The check for correct polarity of connections is particularly important the Check all elements for transportation damages and loose screws or cables Check correct insertion of the multi-pin plugs on PCB’s and of all plug-in relays and units page 21 M311540-17 (383) DC DISTRIBUTION 4.2 Condition Switching ON the busbars for the first time All distribution boards are considered to be completely voltage free and all m.c.b’s, switches and circuit breakers are OFF, the control fuses are inserted The chargers are in operation CAUTION! Some of the distribution boards include remote controlled circuits operated with external control voltages Even with all input feeders open and mcb’s switched off there may be voltage present in the cabinet CAUTION! Before switching on the power to the distribution boards carefully check that all connected consumer are ready to be supplied with power All mcb’s must be open before distributions are supplied with power M311540-17 (384) page 22 DC DISTRIBUTION BUA, BUB (1) Close BUA feeder BUA10GS100 in BUA resp BUB feeder BUB10GS100 in BUB (FA001-Q1) Close the control mcb –F11 The voltmeter P1 show the busbar voltage The LED H21/22 “HIGH/LOW DC VOLTAGE” shall go OFF (2) Close the Cable Feeder mcb’s +BB -F1 one after the other, verify that the relevant consumer is ready The “MCB OPEN” LED H23 will only dissapear when the remaining CB/MCB’s for the inverter feeder BRU10GS101/BRU20GS101 and BUC10 feeder BUC10GS101/102 are closed BUC10 (3) Close the control mcb -F11 for the busbar measuring (4) Close the feeder breaker BUC10GS101 in BUA10 Measure the voltage on terminals +KA001X01/L+ to L- and check the polarity (5) Open the feeder breaker BUC10GS101 in BUA10 and close the feeder breaker BUC10GS102 in BUB10 Measure the voltage on terminals +KA002X01/L+ to L- and check the polarity (6) Close the feeder breaker BUC10GS101 in BUA10 again The LED H11/12(A3) VOLTAGE” shall go OFF page 23 “HIGH/LOW DC M311540-17 (385) DC DISTRIBUTION POWER OIL PUMP ROTOR BARRING (7) Close control mcb +CB-F2 Check the remote order ON/OFF (to relays +CB-K21/22), the contactor +CB-K1 shall operate when the orders are given (8) Close motor feeder mcb +CB-Q1 The LED H31(A4) “ROBA FAILURE” shall go off JACKING OIL PUMP (9) (10) Close control mcb +DB001-F2 Check the remote order ON/OFF (to relays +DB001-K21/22), the contactor +DB001-K1and -K03 shall operate when the orders are given Close motor feeder mcb +DB001-Q1 The LED H32(A4) “JOP1 FAILURE” shall go off JACKING OIL PUMP (11) Close control mcb +DB002-F2 Check the remote order ON/OFF (to relays +DB002-K21/22), the contactor +DB002-K1and -K03 shall operate when the orders are given (12) Close motor feeder mcb +DB002-Q1 The LED H33(A4) “JOP2 FAILURE” shall go off M311540-17 (386) page 24 DC DISTRIBUTION EMERGENCY LUBE OIL PUMP (13) Close the feeder mcb “AUX VOLTAGE ELOP” BUC00GW001 in the inverter distribution BRA10 for the auxiliary AC supply voltage of the emergency lube oil pump (terminals +HB003X1/7-8 in BUC10 shall have 230VAC) (14) Close mcb +FA-F02 and +FA-F03 in BUC10 (15) Set the remanence relay +FA-K44 to position “PS NACT” (Remote controlled via terminals -X55/1-3), relay +FA-K52 shall come on (16) Turn the initialize key-switch +FA-S01 to position „INITIALIZE“ The bar mounted contactor +FA-K03 shall pull in, (i.e the contacts are open) The LED H24(A4) “ELOP OFF” shall be on (17) Close maintenance breaker +FA-Q01 The LED H34(A4) “ELOP FAILURE” shall go off (18) Depending on the status of the turbine: set the remanence relay +FA-K44 to position “PS ACT” (Remote controlled via terminals -X55/2-3) page 25 M311540-17 (387) DC DISTRIBUTION Front panel view BUA/BUB V A BUA10 BUA10 P1 P2 BUA10 H 11 - H21 H IGH D C VOL TAGE H31 - H 12 - H22 L OW DC VOL TAGE H32 - H 13 H 14 - H23 H24 C B/MCB OPEN - - H33 H34 - H 15 - H25 - H35 - L ED T EST S3 M311540-17 (388) page 26 - DC DISTRIBUTION A Front panel view BUC (A3) V A V INP UT FRO M BU A BUC1 INP UT F RO M BUB B UC2 P 11 P1 P1 P2 BUC1 BUC20 H11 HIGH DC VOLTAGE H21 H31 H12 LOW DC VOLTAGE H22 H32 H13 EARTHFAULT + H23 H33 H14 H15 EARTHFAULT - H24 H25 H34 H35 M C B O PE N M CB O PEN LED TES T S3 -A3 page 27 M311540-17 (389) DC DISTRIBUTION A Front panel view BUC (A4) A A A ROBA JOP JOP ELOP P 61 P3 P4 P 51 PUMP CONTROL H1 R OB A ON H21 RO B A O FF H31 R O BA F AIL U RE H1 H1 JO P ON JO P O F F JO P ON H22 H23 H32 H33 J OP F A IL U RE H1 E L OP ON H24 E LO P O FF H34 E LO P F A IL U RE H1 JO P O F F H25 H35 LE D T E ST S3 -A4 M311540-17 (390) page 28 J OP F A IL U RE ... Charger M653006E UPS / Inverter O&M M311540-16 Technical Data UPS / Inverter M311540-17 220V DC Distribution O&M 10 page (2) M311540-11-2 STATRON AG, Switzerland Describtion: Type DC & UPS Revision:... 001 SYMBOLS & LETTERS INDEX A 010 SINGLE LINE 220V DC CHARGER + MAIN DCDB X 011 SINGLE LINE 220V DC SUB-DISTRIBUTION X SINGLE LINE 230V AC UPS + DISTRIBUTION 012 X 020 CONTAINER LAYOUT PANEL... Subcontractor 37 E 38 39 Project 40 41 42 43 Owner's Identification No 44 45 46 F -GT / DC UPS SYSTEM DC / UPS SYSTEM A BTL10, BTM10, BTA10GS100, BTB10GS100 BTA10, BTB10 BUA10, BUB10, BUC10, BUC20