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LIST OF ELECTRICAL STANDARD SPECIFICATIONS 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Codes for electrical equipment Preparation of electrical documents Incoming substations Departmental substations

Medium voltage switchboards Power transformers Power control centres, motor control centres Large motors Small motors Starters Variable speed drives Erection, cabling, earthing connections, lightning protection Production and distribution of auxiliary voltages Electrical cabinets and marshalling cabinets Instrumentation Process Control System : equipment and configuration Process Control System: application software and integration Lighting and power outlets Electrical devices for mechanical equipment Earthing grid Process Control System : basic functional objects Visible Cut-off Switches Incoming transformers

Key codes: Low voltage, Power, Motor Control Centre, MCC, Cabinet F E D C B A 0
Rev

21/10/05 07/10/02
Date

General revision Document edition


Scope of revision

I. MOCANU I. MOCANU
Issued

M. MAHAUX M. MAHAUX
Approved CTI 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 N2 Jalan Kilang 46050 PETALING JAYA SELANGOR DARUL EHSAN MY-MALAYSIA Phone : + 603 77874800 / Fax : + 603 77874890 Reproduction & usage strictly forbidden without Lafarge explicite agreement (Law March 11th, 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

ELECTRICAL STANDARD SPECIFICATION

POWER CONTROL CENTRES, MOTOR CONTROL CENTRES

Document STD002.U07

Page 1/33

Rev. A

CONTENT

1. GENERAL REQUIREMENTS

1.1. APPLICABILITY 4 1.2. APPLICABLE STANDARDS 4 1.3. LOCAL CONDITIONS 4 1.4. GLOSSARY 4 1.5. SIGNS USED 4 1.6. ENCLOSURE AND DEGREE OF PROTECTION 5 1.7. RATED VOLTAGES 5 1.7.1. Main voltage...................................................................................................................... 5 1.7.2. Auxiliary voltages..............................................................................................................5 1.8. RATED INSULATING VOLTAGE 5 1.9. RATED CURRENTS 5 1.10. SHORT CIRCUIT WITHSTAND STRENGTH 6 2. SWITCHBOARD CONSTRUCTION 6 2.1. COMMON REQUIREMENTS 6 2.1.1. General arrangement........................................................................................................6 2.1.2. Switchboard structure........................................................................................................6 2.1.3. Incoming circuit(s).............................................................................................................7 2.1.4. Busbars............................................................................................................................. 7 2.1.5. Control and measuring circuits..........................................................................................8 2.1.6. Remote Input/Output modules...........................................................................................8 2.1.7. Wiring................................................................................................................................ 8 2.1.8. Labels................................................................................................................................ 9 2.2. DRAW-OUT / FIXED TYPES 9 2.2.1. Draw-out type.................................................................................................................... 9 2.2.2. Fixed type........................................................................................................................ 10 3. POWER SWITCHGEAR 3.1. INCOMERS AND BUS-TIE BREAKERS 3.2. OUTGOING CIRCUITS 4. CONTROL SWITCHGEAR AND MEASURING DEVICES 4.1. CONTROL CIRCUITS 4.2. PROTECTIONS 4.3. MEASURING DEVICES 5. PCC/MCC SUPPLYING VSDS 6. POWER FACTOR CORRECTION UNITS 7. DOCUMENTS 7.1. DOCUMENTS TO BE SUPPLIED BY THE OWNER 11 11 11 12 12 13 14 14 15 17 17

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7.2. DOCUMENTS TO BE PREPARED BY THE SUPPLIER 7.3. DOCUMENTS TO BE SUBMITTED WITH THE OFFER 8. FACTORY TESTS 9. GUARANTEE 10. DATA SHEETS 11. SWITCHGEAR SELECTION TABLES 11.1. SWITCHGEAR SELECTION FOR 400 V MOTORS USING LINE STARTERS 11.2. SWITCHGEAR SELECTION FOR 500 V MOTORS USING LINE STARTERS 12. DIAGRAMS

17 18 18 19 19 22 22 24 24

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1.

GENERAL REQUIREMENTS
1.1. APPLICABILITY
This specification is applicable to Power Control Centres (Low Voltage Distribution Boards) as well 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 shall be 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 be installed 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 MCB MCC PCC PCS UPS VCS VSD Auxiliary Control Centre Miniature circuit breaker Motor Control Centre Power Control Centre Process Control System Uninterruptible Power Supply Visible Cut-Off Switch Variable Speed Drive

1.5. SIGNS USED


A sign in the margin will mark up in the text of this specification each clause to be mandatorily specified 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 IP31 according 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 in Specification STD.002.U13. A

1.8. RATED INSULATING VOLTAGE


The insulation voltage for the busbars and power switchgear as well as for any circuit of the switchboard shall not be less than: Busbars: Power switchgear: Power circuits: Control switchgear and circuits: 1 000 V 690 V 750V 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 feeding transformer 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 cross section 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 shortcircuit current mentioned in the particular specification and shall in no case be less than 50 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 either in one line or back to back (busbars shall be independent and segregated). The main busbar shall 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 for easy 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 for manoeuvring 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 acrylourethane 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 less than 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 copper earth collector connected 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. The cross section of this earth collector shall be such that it will withstand the switchboards shortcircuit 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 power connections). Each access door shall 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 by busbar provided with flexible connection or by cables.

2.1.4. Busbars
Main busbars (horizontal) and vertical busbars shall be of electrolytic copper type 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 of the switchboard. Every signalling switchgear 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 of each switchboard section, in a compartment separate by a metal sheet from the portion devoted 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
A 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 larger cables ; Control terminals : shall be of insulation displacement type (needing no special tool for completing the connection) or of spring type. Connectors with plug and sockets (several stages if necessary) shall be provided for control 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 any accidental 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 is connected to, according to manufacturers standard procedures. Wires shall be installed in trunkings 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 and indicating 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 bar rated currents, short circuit withstand current. Section (column) number label installed on the upper middle front part of each section or of its door. Module (plug-in type) or drawer (draw-out type) tag label to be secured to the fixed part facing to corresponding module or drawer, indicating the tag (Lafarge code) and the description 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


A 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 and inserted 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 or manually by disconnecting a plug where pass all the control circuits through. Such disconnection/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


A 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 fully equipped 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 without switching off the switchboard. Evolution : new outgoing circuits can be installed, if spare spaces exist, without switching 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 another outgoing circuit or with switchboard common circuits shall be performed without passing through 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 switchboard section supporting outgoing circuits shall be equipped with a safety glass door with a rubber seal.

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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 protected on upstream side (for instance by a circuit breaker connected to the secondary winding of the feeding transformer) power switches (or circuit breakers without protection relays) shall be installed 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 main busbar; in case of power failure from the emergency generator. Changeover shall be by 2 circuit breakers or contactors mechanically interlocked to avoid paralleling these 2 sources. If neutral is isolated, an insulation check meter shall 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 switchboards terminals.

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 to withstand the full short circuit current. Its protection system shall be co-ordinated with cables core section and cables length according to IEC rules (short-circuit condition, overload condition, voltage drop, installation conditions, protections against indirect contacts, ...). Its handle shall provide for locking 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 also be 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 or electronic 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 with following 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 protection system 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 these spare 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 0.5 sec). The contact of this relay shall be connected in the series with the emergency shut-down contacts. 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 contacts of the switchboard system shall be wired to switchboards terminals in order to inform the PCS. 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 circuit breaker 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 section 12).

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 from the rest of the section. These modules will communicate with the PCS. Unless otherwise mentioned, 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 cabling and be able to perform a maximum of tests at the workshop. Alternatively, for incoming circuits, the metering units mentioned in section 4.2 can be used 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 be possible 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 START and 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 be performed by the cabling contractor).

4.3. MEASURING DEVICES


Every current transformer shall 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. This shall measure at least following parameters : 3U, 3V, 3I, P, Q, S, f and PF and display these parameters (according to operator selection). This unit shall also meter active and reactive energies and provide a pulse output for active energy. This metering unit shall also monitor the presence of the three phases and send an alarm through the fieldbus (see below) in the absence of one or several phases, or in case of failure of this device. It shall include communication with the PCS by a fieldbus PROFIBUS DP. On this fieldbus shall 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, ) of any power shall be equipped with a current transducer converting the full motor current range in a 4-20 mA DC signal connected to the plant control system through outgoing terminals and to a current indicator installed on the drawer front/plate or adjacent to it. The current transducer and the current indicator shall be replaced by an active power transducer and an active power indicator for 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). Their simultaneously 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 bar shall be balanced as far as possible. A single line diagram of the switchboard shall be submitted to the Owners approval.

6.
A

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 factor of the switchboard from natural value (typically 0.7) up to 0.92 unless more stringent requirements 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 rated power (kVA) 630 1000 1250 1600 2000 2500 Power factor correction unit rated power required (kVAR) 275 425 520 675 850 1050

This power factor correction unit shall be of automatic type, connecting or disconnecting the capacitor banks by steps according to power factor fluctuations. Steps shall not exceed 50 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 with the 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 k between the power of harmonics generated and the power of the transformer feeding the PCC/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 with all 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 Site Specification) 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 that the 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 be separately packed for despatch and a detailed test procedure be submitted to the Owner prior starting 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 the switchboard. 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 Owners representative 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 months after the switchboards are ready for factory tests.

10.

DATA SHEETS

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CUSTOMER: PROJECT: DATA SHEET POWER CONTROL CENTRE, MOTOR CONTROL CENTRE EQUIPMENT: Type Draw-out/Plug-in 1 2 3 4 5 6 Protection degree Segregation Service index Manufacturer Cabinets Switchgear Service conditions Rated voltage IP Form IS

SUPPLIER : PROJECT No: OFFER: DATE :

8 9

Insulation voltage

10 11 12 13 14 15 16 17 18 19

Short-time withstand current Incoming circuit Rated current of main circuit breaker Short circuit current of main circuit breaker Feeder by busbar/cables Measurement device Insulation checkmeter (if applicable) Busbars Main busbars (horizontal) rated current Material / cross section Secondary busbars (vertical) rated current Material / cross section Maintenance required Control

kA A kA

A A

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20

Remote I/O modules / intelligent switchboard

21 22 23 24 25 26 27 28 29 Accessories Anti-condensation heaters required Others Dimensions Switchboard height Switchboard depth Switchboard length Cable channel width Painting Preparation Finish Deviations from this specification Yes/No Yes/No mm mm mm mm

CUSTOMER: PROJECT: DATA SHEET LV POWER FACTOR CORRECTION UNIT EQUIPMENT: 1 Type 2 Manufacturer 3 Rated voltage 4 Insulation voltage 5 Total capacity 6 Capacity of each step Power factor regulation 7 Regulation load relays in each unit 8 Remote turn on and off Protection against harmonic currents 9 Reinforced protection 10 Anti-harmonic inductance 11 Anti-harmonic filters Dimensions 12 Cabinet height 13 Cabinet depth 14 Cabinet length Painting 15 Preparation Finish 16 17 Deviations from this specification

SUPPLIER : PROJECT No: OFFER: DATE :

V V kVAr kVAr V Yes/No Yes/No Yes/No Yes/No Yes/No mm mm mm

POWER CONTROL CENTRES, MOTOR CONTROL CENTRES

Document STD.002.U07

Page 21/33

Rev. A

Notes: 1.

Values to be mentioned in boxes marked with sign are to be given by the Owner or by the main Contractor. 2. The Supplier is requested to fill in a data sheet for each type of equipment proposed and to return it with its proposal.

11.

SWITCHGEAR SELECTION TABLES

11.1. SWITCHGEAR SELECTION FOR 400 V MOTORS USING LINE STARTERS


Current (A) 0.8 1.1 1.6 2 2.5 3.3 4.6 6.0 8.4 11 15 20 28 34 40 47 55 66 100 C-breaker * 1 1.6 1.6 2.5 2.5 4.0 6.0 6.0 10 13 18 25 32 40 50 1

P (kW) 0.25 0.37 0.55 0.75 1.1 1.5 2.2 3 4 5.5 7.5 11 15 18.5 22 25 30 37 55

Contactor 25 25 25 25 25 25 25 25 25 25 25 40 40 63 63 80 80 115 185

Thermal 0.63 1.00 1.00 1.60 1.60 2.50 4.00 4.00 7.00 10.0 13.0 18.0 23.0 30.0 38.0 0.63 to to to to to to to to to to to to to to to to " " "

CT Ratio

50/1 60/1 100/1 125/1

POWER CONTROL CENTRES, MOTOR CONTROL CENTRES

Document STD.002.U07

Page 22/33

Rev. A

75 90 110 132 160 200 250

128 156 205 224 280 349 434

185 265 265 400 400 400 630

" " " " "

150/1 200/1 250/1 250/1 300/1 400/1 630/1

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

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

POWER CONTROL CENTRES, MOTOR CONTROL CENTRES

Document STD.002.U07

Page 23/33

Rev. A

11.2. SWITCHGEAR SELECTION FOR 500 V MOTORS USING LINE STARTERS


Current (A) 0,8 1,1 1,6 2 2,5 3,3 4,6 6 8,4 11 15 20 28 34 40 47 55 66 80 100 128 156 224 280 C-breaker *

P (kW) 0,25 0,37 0,55 0,75 1,1 1,5 2,2 3 4 5,5 7,5 11 15 18,5 22 25 30 37 45 55 75 90 132 160

contactor 25 25 25 25 25 25 25 25 25 25 25 40 40 63 63 80 80 115 185 185 185 265 400 400

Thermal 0,63 to 1 1,00 to 1,6 1,00 to 1,6 1,60 to 2,5 1,60 to 2,5 2,50 to 4 4,00 to 6 4,00 to 6 7,00 to 10 10,00 to 13 13,00 to 18 18,00 to 25 23,00 to 32 30,00 to 40 38,00 to 50 0,63 to 1 " " " " " " " "

CT ratio

50/1 60/1 80/1 100/1 125/1 150/1 200/1 250/1 300/1

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

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

12.

DIAGRAMS

POWER CONTROL CENTRES, MOTOR CONTROL CENTRES

Document STD.002.U07

Page 24/33

Rev. A

MCC single line diagrams in 2 versions : Either the emergency generator feeds the essential users through the normal busbar of the 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 users from the emergency generator, the other users being connected to the normal busbar not 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

POWER CONTROL CENTRES, MOTOR CONTROL CENTRES

Document STD.002.U07

Page 25/33

Rev. A

MOTOR CONTROL CENTRE


Typical single line diagram without LV emergency supply

Main Horizontal Busbars


MEASURING MODULE (KY)

PE

MOTOR STARTER MODULES

PACKAGE

FEEDING ESSENTIAL CONSUMERS 400V

By- Pass

INCOMING FEEDER

3 CAPACITOR BANK STEP REGULATION ACCORDING TO PF & LOAD

POWER CONTROL CENTRES, MOTOR CONTROL CENTRES


TN-S NETWORK NEUTRAL CONDUCTOR NOT DISTRIBUTED

Auxiliary Transformer (TF)


230Vac 230Vac UPS (UP)

DISTRIBUTION TRANSFORMER (TF) MEDIUM/LOW VOLTAGE

Document STD.002.U07

Page 26/33

Rev. A

MOTOR CONTROL CENTRE


Typical single line diagram with LV emergency supply

Main Horizontal Busbars


MEASURING MODULE (KY)

Emergency Horizontal Busbars

PE

PE

MOTOR STARTER MODULES

PACKAGE

FEEDING ESSENTIAL CONSUMERS 400V

By- Pass

INCOMING FEEDER

3 CAPACITOR BANK STEP REGULATION ACCORDING TO PF & LOAD

POWER CONTROL CENTRES, MOTOR CONTROL CENTRES


3
TN-S NETWORK NEUTRAL CONDUCTOR NOT DISTRIBUTED

Auxiliary Transformer (TF)


230Vac 230Vac UPS (UP)

DISTRIBUTION TRANSFORMER (TF) MEDIUM/LOW VOLTAGE

Document STD.002.U07

EMERGENCY GENERATOR

Page 27/33

Rev. A

Busbar 1 Busbar 2 Fast fuses

MCC 316MC13-VSD Kiln Downstream (MOTOR example)CONTROL CENTRE

400V

Note: fast fuses for VSD protection

IM-Insulation Monitoring

IM 3

IM 3

POWER CONTROL CENTRES, MOTOR CONTROL CENTRES


1000A

Surge arrester

1000A

MV/ LVormer transf

M
3*30kW 318HE01MT10 318HE01MT11 318HE01MT12 3*30kW 318HE01MT13 318HE01MT14 318HE01MT15 3*30kW 318HE01MT16 318HE01MT17 318HE01MT18

3*30kW 318HE01MT19 318HE01MT20 318HE01MT21

316AB13MT1075kW

317FA03MT10 75kW

317FA05MT10 132kW

317FA07MT10 110kW

Document STD.002.U07

Page 28/33

Rev. A

400 V 0V
-Q11 -Q1
Yellow Green Red

230V ac Typical schematic diagram - Motor 1 direction - K1 type

+24V dc

MOTOR CONTROL CENTRE


Drawer or Plate I/O Compartment Digital output
-KA1

-Q12

Precut-off

To Q1 Trip Available Running Failure

12 10

C1

Start Command

-KM1

Digital input
1 7 4 3 2

AV

Availability

-F1

-KA1 -KB -F1 -KM1 -KB -KM1

-Q1 Trip

B1 L1 LS HS

Feedback Local Start Local Stop Emergency Shut-Down

H Heavy start (if any) I J 1 Power measure 3 4 2 Current measure or

Motor Operating Mode :


Choice of Sequential/ Local mode is made by operator on the Operator Station

Field

POWER CONTROL CENTRES, MOTOR CONTROL CENTRES


Visible Cut-off Switch
L1 LS
Pre-Cut off 3 Padlocks 2 7 Cable- Loop 8

Marshalling Board

Digital input
S Speed monitor

HS M 3

E Emergency Shut-Down

pull rope (if applicable)

24V dc

XS XXnn

Speed switch Other machine sensors

Analogue input
YI Motor Current or Power

Document STD.002.U07

Page 29/33

Rev. A

400 V 0V Typical schematic diagram - Motor 2 directions - K2 type


-Q11 -Q1
Yellow Green Green Red

230V ac

+24V dc

MOTOR CONTROL CENTRE


Drawer or Plate I/O Compartment Digital output
-KA2 -KA1
12 10 13 11

-Q12

Precut-off

To Q1 Trip Available Failure

C1 C2

Start Command Direction 1 Start Command Direction 2

Running Direction 1

-KM1

-KM2

Running Direction 2

Digital input
1 7 8

AV B1 B2

Availability Feedback Direction 1 Feedback Direction 2

-F1

-KM2 -KA1 -KB


H Heavy start (if any)

-KM1 -KA2 -KM2 -KB -KM1 -KM2 -Q1 -F1 Trip

3 4 5 2

-KM1

LS L1 L2 HS

Local Stop Local Start Direction 1 Local Start Direction 2 Emergency Shut-Down

/
J 1 4 Power measure 5

Current measure or

Motor Operating Mode :


10 11 3 2 Choice of Sequential/ Local mode is made by operator on the Operator Station

Field

10

11

Visible Cut-off Switch


L1 L2
3

POWER CONTROL CENTRES, MOTOR CONTROL CENTRES


LS
Pre-Cut off 3 Padlocks 7 Cable- Loop 8 2

Marshalling Board

Digital input
HS
E Emergency Shut-Down

M 3

pull rope (if applicable)

S Speed monitor

24V dc

XS XXnn

Speed switch Other machine sensors

Analogue input
YI Motor Current or Power

Document STD.002.U07

Page 30/33

Rev. A

400 V 0V Typical schematic diagram - Actuator 2 positions - KM type

230V ac

+24V dc

MOTOR CONTROL CENTRE


Drawer or Plate I/O Compartment Digital output
Green Green Red

-Q1
Yellow

Precut-off -KA2 To Q1 Trip Available Failure -KA1

12 10 13 11

C1 C2
1

Start Command Direction 1 (open) Start Command Direction 2 (close)

Running Direction 1

-KM1

-KM2

Running Direction 2

Digital input
7 8 14

AV

Availability

-F1

-KM2 -KA1 -KB -KM1 -KM2 -KA2 -KB -F1 -KM1 -KM2 - Q1 Trip

-KM1

15 9 3 4 5

B1 B2 XZ10 XZ20 XX10 LS L1 L2

Feedback Direction 1 Feedback Direction 2 Position 1 switch (open) Position 2 switch (close) Torque switch (if any) Local Stop Local Start Direction 1 (open) Local Start Direction 2 (close)

Motor Operating Mode :


1 4 5 10 11 9 3 Choice of Sequential/ Local mode is made by operator on the Operator Station

Field

Actuator

XZ10
1 4 5
Position1

XZ20
Position2

10

11 9

POWER CONTROL CENTRES, MOTOR CONTROL CENTRES


Visible Cut-off Switch
L1 L2
3

Marshalling Board
Torque switch LS
Pre-Cut off

Digital input
XXnn Other machine sensors

24V dc Analog input


YZ10 Position Feedback
7 8

3 Padlocks

Cable- Loop

Analogue output
3 M ZC Position set point

Document STD.002.U07

Page 31/33

Rev. A

400 V 0V
-Q11 -Q13 -Q12
Yellow Green Red

230V ac 230V UPS

+24V dc

MOTOR CONTROL CENTRE


Typical schematic diagram - Motor speed variation - VS type Drawer or Plate Note: fast fuses for VSD protection
12 10

I/O Compartment Digital output

-Q1 -KA1 To Q1 Trip

Precut-off

C1

Start Command

Available

Running

Failure

-KM1

Digital input
1 7 4 3 16 6 2

AV

Availability

-F1

-KA1 -KA1 -F1 -KB -KM1 -KB -KM1

- Q1 Trip

B1 L1 LS LU LD HS

Feedback Local Start Local Stop Local Speed-up Local Speed-down Emergency Shut-Down

-C1

Motor Operating Mode :


Choice of Sequential/ Local mode is made by operator on the Operator Station

16

Fieldbus to PCS controller


1 3 4 16 6

POWER CONTROL CENTRES, MOTOR CONTROL CENTRES


Field Visible Cut-off Switch
L1 LU LD LS
Pre-Cut off 3 Padlocks 2 7 Cable- Loop 8

Marshalling Board

Analog input
YI YS HS M 3
E Emergency Shut-Down To VSD inside MCC

Motor Current or Power Speed feedback

Analogue output
pull rope (if applicable) SC Speed set-point

Document STD.002.U07

Page 32/33

Rev. A

400 Vac

MOTOR CONTROL CENTRE


Typical schematic diagram - Package circuit breaker - Q type Drawer or Plate I/O Compartment
Digital input 24V dc

Q1 AV Availability

/
J Power measure

Current measure or

POWER CONTROL CENTRES, MOTOR CONTROL CENTRES


Field Visible Cut-off Switch
3 Padlocks

Marshalling Board

Analogue input YI Current or Power

Document STD.002.U07
PACKAGE

Page 33/33

Rev. A