SINCOR

Project Title: SINCOR, C. A.

Sincor Document No:
Sincor Interface Code:
Sincor Document CLASS:
CA04-04-33-P-SP-005
0
00
UPSTREAM SURFACE FACILITIES Page /File: 1/CA040433PSP005
Rev./Date: X3 / 26 Mayo 2006

SINCOR, C.A.
UPSTREAM SURFACE FACILITIES PROJECT

LOW VOLTAGE MOTOR CONTROL CENTERS

REVISION INDEX:
This Document Consists of 13 Pages

Note: Any Technical change from the original Sincor document is indicated by in the right hand
margin.

APPROVAL REGISTER

Rev. Prepared By/ Checked By/ Project Approved By/ Reason for
No. Date Date Approved By/ Date Revision
Date
A0 K. FILIPCHUCK D. BAILLIE Issued for IDC
99.02.22 99.02.23
0 K. FILIPCHUCK D. BAILLIE B. DOCHERTY Issued for RFQ
99.03.04 99.03.04 99.03.06
1 L. NEILSON D. BAILLIE R. Issued for
99.06.10 99.06.10 CALDWELL Purchase
99.06.10
X0 A. AVILA A. AVILA J.
14.10.03 14.10.03 MORILLO As Built update
14.10.03 by SINCOR
X1 A. Avila A. Avila S. Cuesta J. Riera Update by
17/10/2004 17/10/2004 17/10/2004 17/10/2004 SINCOR
Rev. 2004
X2 A. Avila A. Avila S. Cuesta J. Riera Update by
29/08/2005 29/08/2005 29/08/2005 29/08/2005 SINCOR
Rev. 2005
X3 M. Bazaco A. Avila S. Cuesta J. Riera Update by
26/05/2006 26/05/2006 26/05/2006 26/05/2006 SINCOR
Rev. 2006

CA04-04-33-P-SP-005_X3 1 - 13
SINCOR
Project Title: SINCOR, C. A.
Sincor Document No:
Sincor Interface Code:
Sincor Document CLASS:
CA04-04-33-P-SP-005
0
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UPSTREAM SURFACE FACILITIES Page /File: 2/CA040433PSP005
Rev./Date: X3 / 26 Mayo 2006

TABLE OF CONTENTS

1. SCOPE .........................................................................................................................................3

2. GENERAL ....................................................................................................................................3

3. ELECTRIC CHARACTERISTICS .................................................................................................3

4. MECHANICAL AND ELECTRICAL FEATURES ..........................................................................3

5. MOTOR CONTROL UNITS..................................................................................................................6

6. INCOMING FEEDER...................................................................................................................12

7. FEEDERS TO USERS ................................................................................................................12

8. INSTRUMENT TRANSFORMERS ..............................................................................................13

9. BUSES ........................................................................................................................................13

10. NAMEPLATES ............................................................................................................................13

11. ACCESSORIES...........................................................................................................................13

12. TESTS .........................................................................................................................................13

13. DRAWINGS AND TECHNICAL DOCUMENTATION ..................................................................13

CA04-04-33-P-SP-005_X3 2 - 13
SINCOR
Project Title: SINCOR, C. A.
Sincor Document No:
Sincor Interface Code:
Sincor Document CLASS:
CA04-04-33-P-SP-005
0
00
UPSTREAM SURFACE FACILITIES Page /File: 3/CA040433PSP005
Rev./Date: X3 / 26 Mayo 2006

1. SCOPE

This specification covers the particular requirements for the design, manufacturing, connection
and testing of Low Voltage Motor Control Centers (LVMCC), withdrawable units type, for
indoor installation, in non hazardous locations and corresponds to minimum requirements.
MCC shall fully comply with the requirements of the Electrical Switchboard Specification CA04-
04-33-P-SP-001, which shall be considered an integral part of this specification.

2. GENERAL
A. This specification will be supplemented for use in conjunction with the Material
Requisition (MR), one line diagram and Data Sheet.

B. Should conflict exist between this specification and the Specification CA04-04-33-P-SP-
001, the former shall govern; furthermore, should conflict exist among Specification
CA04-04-33-P-SP-001, this specification and the MR or Data Sheet, the MR or Data
Sheet shall govern. In case of doubt Vendor shall notify to the buyer in writing for
resolution.

C. Applicable codes and standards shall be those listed in Specification CA04-04-33-P-

SP-001, unless otherwise specified in the MR.

D. The assembly shall be suitable to form part of a system with coordinated insulation
values in accordance with IEC - 60664 and IEC - 60664A, and shall be type tested
accordingly.

3. ELECTRIC CHARACTERISTICS
A. General

The MCC and components shall be of, or modification of, the manufacturers standard
product line in order to facilitate future modifications and procurement of spare parts.

B. All equipment shall be fully rated for the available short circuit capacity of the bus
system. Cascading is not acceptable.

4. MECHANICAL AND ELECTRICAL FEATURES

A. General Characteristics

a) The complete MCC shall be formed by multiple vertical sections joined together
and shall be single front type.

Single front type MCCs shall be suitable for back-to-back mounting, as long as
you can access bus bars for maintenance.

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SINCOR
Project Title: SINCOR, C. A.
Sincor Document No:
Sincor Interface Code:
Sincor Document CLASS:
CA04-04-33-P-SP-005
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UPSTREAM SURFACE FACILITIES Page /File: 4/CA040433PSP005
Rev./Date: X3 / 26 Mayo 2006

b) The MCC shall be totally enclosed dead front, unit designed, factory built and
assembled. It shall be made of free-standing welded steel vertical sections
joined together to form a complete assembly. Any insulation material used shall
have flame retardant properties and shall be as halogen free as is practical.
Each vertical section shall be provided with a removable bottom plate.

c) The larger size units shall preferably be installed in the lowest locations.

d) Future extension on both ends shall be possible in accordance with

Specification CA04-04-33-P-SP-001.

B. Mechanical Features

Each section shall be an enclosed, free standing, floor mounted sheet metal structure.

a) Each section shall be arranged to house:

motor control units (any combination of different standard sizes of

control units shall be possible),

the main horizontal busbar connecting one section to the adjacent

sections,

the vertical branch busbars feeding the motor control units,

wiring troughs and terminal blocks for power and auxiliary cables.

b) A vertical cableway, complete with cable and wire retainer straps, running along
the full working height shall be provided on one side of each section. The
cableway shall be at least 200 mm wide x 300 mm deep and shall be provided
with its own door.

It shall be possible to connect power and auxiliary cables to a terminal block of

a unit without interferences with the adjacent power and control cables with the
MCC normally energized.

c) A horizontal cableway shall be provided on the top of the section for

interconnecting wiring among sections.

d) Both the vertical and the horizontal cableway shall be easily accessible from the
front of the board (horizontal wireway may be accessible from the top) without
deenergizing the MCC, but only by removing covers or by withdrawal of the unit
concerned.

e) The busbars, the feeder units and the cableway shall be separated from one
another by means of suitable barriers (refer to Specification CA04-04-33-P-SP-
001).

CA04-04-33-P-SP-005_X3 4 - 13
SINCOR
Project Title: SINCOR, C. A.
Sincor Document No:
Sincor Interface Code:
Sincor Document CLASS:
CA04-04-33-P-SP-005
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UPSTREAM SURFACE FACILITIES Page /File: 5/CA040433PSP005
Rev./Date: X3 / 26 Mayo 2006

f) The vertical busbars and all fixed electrical connections shall be accessible from
the front for inspection, maintenance etc. by the withdrawal of the units and the
removal of protective barriers and covers.

g) Modular construction shall be employed throughout the MCCs so that changes

in the layout of the units after erection of the MCC in the field may be easily
accomplished.

h) The front of each unit and terminal chamber shall be closed by panel type flush
hinged doors. Such doors are not required when each motor withdrawable
control unit is fitted with a front panel which is a part of the units structure.

Any blank module shall be closed by a door or a bolted panel.

i) Internal Separation of Assemblies

It is acceptable that outgoing terminals of functional units are installed in

combined compartments provided that all terminations have a minimum degree
of protection of IP-30. The partition shall comply with the degree of protection of
IP-40 for the following:

between horizontal busbar compartments and any other compartments;

between incoming and sectionalizer units;

between main busbar systems of two separate sections;

between compartment of each functional unit towards other

compartments.

Connection of field cables to the starters and feeders shall be possible

conveniently from the front of the MCC via the vertical cable
compartment. Cable fastening facilities shall be provided within the
cubicle and termination lugs, where required, shall be furnished.

When motor starter unit is in the test position, the degree of protection
shall be at least IP-20.

C. Busbars

The requirements of the Specification CA04-04-33-P-SP-001 shall be met.

D. Earthing

An earthing switch for outgoing feeders is not required.

CA04-04-33-P-SP-005_X3 5 - 13
SINCOR
Project Title: SINCOR, C. A.
Sincor Document No:
Sincor Interface Code:
Sincor Document CLASS:
CA04-04-33-P-SP-005
0
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UPSTREAM SURFACE FACILITIES Page /File: 6/CA040433PSP005
Rev./Date: X3 / 26 Mayo 2006

5. MOTOR CONTROL UNITS

A. General

a) Each control unit shall consist of a rigid metal chassis, containing all devices
required for the control of a user.

Guides shall be provided in the structure for supporting and aligning when
removing or replacing a unit.

b) The units shall have standard modular sizes. The units of the same size shall be
quickly and easily interchangeable.

Each unit shall be equipped with basic device terminals, fuse blocks, isolating
plug contacts, etc., suitable for the maximum allowable power rating of the size
concerned.

c) The lowest size unit shall have a rated power capacity of at least 15 kW at 480
V - 60 Hz. Units with a rated power capacity lower than 15 kW shall be
accepted only for MCCs each having more than four users rated less than 15
kW at 480 V - 60 Hz.

d) All units whose contactor coils power consumption during closing exceeds 500
VA with control voltage equal to or less than 120 V - 60 Hz shall have space
provision for an auxiliary relay.

e) Motor starters shall be direct on-line unless specified otherwise - see Data
Sheet.

f) Thermal, three phase overload relays incorporating single phasing protection

and ambient temperature compensation shall be provided. Where appropriate,
the protection relay shall be fed from current transformers.

g) As a minimum, motors of 15 kW (20 HP) and above installed in Main Station

and motors of 30 kW (40 HP) and above installed in Clusters and outside area
from Main Station, shall be fitted with core balance type ground fault protection
relays, or the ground fault protection can be incorporated into a solid state motor
protection relay. Relays shall be manually resetable. The relays shall operate
on an earth fault current of less than 3% of the rated nominal motor current with
a maximum of 6A. The relays shall be equipped with a trip indication on the
relay and on the front of the compartment if relay trip light is within the
compartment.

h) Motor protection relays shall be hand reset. Reset pushbuttons for overload
protection shall be external to the compartment. Reset for earth fault protection
shall not be accessible externally.

CA04-04-33-P-SP-005_X3 6 - 13
SINCOR
Project Title: SINCOR, C. A.
Sincor Document No:
Sincor Interface Code:
Sincor Document CLASS:
CA04-04-33-P-SP-005
0
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UPSTREAM SURFACE FACILITIES Page /File: 7/CA040433PSP005
Rev./Date: X3 / 26 Mayo 2006

i) Motor starter units and feeder units shall be furnished in interchangeable

combinations of the line plug-in type with silver-plated pressure type line
disconnecting stabs for both busbar and outgoing feeder connections.

j) The disconnect handles shall be spring-loaded in such a manner that the handle
will not indicate a safe condition when the device is closed.

k) Variable Speed Electrical Power Drives (PDSs) and Electronic Soft Starters
shall be incorporated into the MCC design as required.

l) Terminals of equipment installed on a compartment door and which can be alive

when the door is opened, shall be shrouded to a degree of protection of a least
IP-30.

m) For motors with excessive acceleration times, an electronic protection relay with
suitable protection curves shall be supplied.

B. Type of Control Units

a) Each control unit shall be drawout completely removable type.

This kind of unit shall have three positions mechanically and electrically well
defined, namely:

connected (or engaged);

disconnected position;

test position.

Units shall offer control and maintenance facilities similar to a circuit breaker, as
described in the Specification CA04-04-33-P-SP-001.

It shall be possible to close the door if the unit is in disconnected and in test
position and to padlock the unit in all positions. If the front panel is integral with
the drawer, equivalent operation shall be permitted. Vendor to specify details.

b) The outgoing control cables shall preferably be a set of plug-in contacts,

however, pull-apart terminal blocks shall be acceptable.

C. Interlocks

a) A mechanical interlock between the door and the unit shall prevent opening of
the door:

if the unit is provided with isolator or circuit breaker when the unit
disconnected device is closed,

CA04-04-33-P-SP-005_X3 7 - 13
SINCOR
Project Title: SINCOR, C. A.
Sincor Document No:
Sincor Interface Code:
Sincor Document CLASS:
CA04-04-33-P-SP-005
0
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UPSTREAM SURFACE FACILITIES Page /File: 8/CA040433PSP005
Rev./Date: X3 / 26 Mayo 2006

if the unit is not provided with a disconnect device, when the unit is in the
inserted position.

In addition, for starter-fuse combinations without a disconnect switch, a

mechanical interlock is preferred so that they cannot be withdrawn to disconnect
their plug-in contacts when the starter magnet structure is closed. Alternatively,
a LED or similar long-life pilot light, energized from the load side of the starter to
warn if the starter remains closed after its coil has been deenergized, is
acceptable. It is preferred that a pilot light be mounted on the starter assembly
and be visible through an opening in the access door rather than be mounted on
the door.

However, a release mechanism to permit authorized personnel to open the door

shall be provided. This mechanism shall be operable only by means of a hand
tool e.g. screwdriver.

If the front panel is integral with the drawer, equivalent safety conditions shall be
assured; vendor to specify details.

b) The isolator switch shall be in OFF position before the unit can be withdrawn.

c) The unit shall be equipped with guides or rails to ensure positive alignment of
the plug-in contacts.

The male part of the pull apart terminal block (or plug) shall be fixed to the unit
structure. The female part shall be fixed to the cubicle in floating manner, i.e.
providing tolerance for alignment between the unit guide rails and plug pins.

It shall also be possible to unbolt or similarly remove the female plug from the
unit, in order to permit checking or altering of the wiring.

D. Test Position

a) Test facility shall be such that when being used the power circuit is deenergized
and the auxiliary circuits connected.

b) Test operations shall be performed either by means of a pushbutton unit to be

plugged into a test double pole socket, fixed either to the door or inside the unit
in an accessible position, or by the normal means of control through a selector
switch having normal service and test positions.

Attention shall be paid to interlocks with other units and monitoring tags shall be
provided.

E. Main Components in the Units

As specified in the Data Sheet, typical motor control units shall be comprised of the
following:

CA04-04-33-P-SP-005_X3 8 - 13
SINCOR
Project Title: SINCOR, C. A.
Sincor Document No:
Sincor Interface Code:
Sincor Document CLASS:
CA04-04-33-P-SP-005
0
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UPSTREAM SURFACE FACILITIES Page /File: 9/CA040433PSP005
Rev./Date: X3 / 26 Mayo 2006

Molded case breaker combination starters;

Fused switch combination starters;

Molded case breakers;

Fused switches;

and equipped with:

a) Short circuit protection and disconnecting means; they shall be in accordance

with the Data Sheet and/or typical one line drawings attached to it.

One of the following three alternatives may be considered:

No disconnect device, three power fuses (current limiting type). The

fuses shall be plug type for the lowest size units (up to 15 kW - 480 V -
60 Hz rating) and cartridge type for higher sizes;

Triple pole disconnect switch, which opens and closes its contacts with a
quick make and quick break operation (*), combined with fuses as per
above point a.;

Molded case triple pole automatic circuit breaker fitted with thermal and
magnetic release and, if required, integral current limiting fuses.

If no indication about the alternative to be used is given, the second solution

shall be adopted. Operation of disconnect switches and circuit breakers shall
be by means of external handles, mounted on the door, or front panel, which
shall also indicate the position (closed or open) of the actuated device. Both
disconnect and circuit breaker shall be padlockable in open and closed
positions.

(*) Make and break capacity at least equal to 1.5 times the maximum size
motor break away current; short circuit capability corresponding to fuses limited
current.

Motor starter disconnecting devices, if required, shall be manually

operated air circuit breakers.

Disconnecting devices shall be capable of interrupting motor locked rotor

current.

b) Three-pole magnetic contactor, rated for continuous operation, with double air-
break contacts and fitted with triple pole thermal overload relay.

CA04-04-33-P-SP-005_X3 9 - 13
SINCOR
Project Title: SINCOR, C. A.
Sincor Document No:
Sincor Interface Code:
Sincor Document CLASS:
CA04-04-33-P-SP-005
0
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UPSTREAM SURFACE FACILITIES Page /File: 10/CA040433PSP005
Rev./Date: X3 / 26 Mayo 2006

Thermal relay shall be temperature compensated with a time-current

characteristic consistent with the user requirements, and shall have a
selector for hand reset operation (hand reset may be provided within
the cubicle - refer to Specification CA04-04-33-P-SP-001).

Thermal relay shall have a change over contact.

Contactor shall close positively with 85% of rated coil voltage and shall
be maintained positively with a voltage-drop up to 65% of the rated
voltage.

Contactor shall be provided with at least two make and two break
auxiliary contacts (refer to Specification CA04-04-33-P-SP-001).

When power fuses are used in the unit, single phasing protection shall
be provided, if specified in the MR.

On-off position indication of contactors shall be fitted on the front of each

compartment by a red light for ON and a green light for OFF.

If winding temperature detectors for tripping are provided in the motor,

the thermal overcurrent relays may be omitted. If specified, as for
canned pump-motor application, the trip signal from a thermistor type
winding temperature trip shall be made manual reset and indicating at
the starter; if an additional trip is provided, such as vapor sensing it shall
also be made indicating and hand reset at the starter (indicator shall be
separate, but reset may be common).

F. Auxiliary Components in the Units

a) Unless otherwise specified in the MR, typical motor control units shall include:

test socket for external test pushbutton;

an auxiliary control transformer;

one current transformer for remote ammeter, rated 5A secondary, if

specified in the MR;

one auxiliary contactor, if required;

one emergency pushbutton for tripping the unit contactor where no

disconnect is present;

other pushbuttons and/or indicating lamps mounted on the front, as

specified in the MR and attached drawings;

CA04-04-33-P-SP-005_X3 10 - 13
SINCOR
Project Title: SINCOR, C. A.
Sincor Document No:
Sincor Interface Code:
Sincor Document CLASS:
CA04-04-33-P-SP-005
0
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UPSTREAM SURFACE FACILITIES Page /File: 11/CA040433PSP005
Rev./Date: X3 / 26 Mayo 2006

nameplate tagged with the ITEM and SERVICE of the fed user.

b) The auxiliary control transformer shall be protected both on primary and

secondary side by means of 480-120V AC 60 Hz, suitably rated fuses. The
secondary side shall be earthed. The size of auxiliary control transformer shall
be adequate to operate its designated equipment, plus 25 VA extra capacity for
external device (by user).

c) Control power transformer, 480 V - 120 V, shall be provided separately in each

starter.

d) Starter coils supplied at system voltage and protected by control circuit fuses
shall preferably be supplied line-to ground. Coils supplied at system line-to-line
voltage and protected by control circuit fuses shall have operating
characteristics or their control circuits arranged to ensure they drop-out should
one control circuit fuse operate and leave the coil energized at system line-to-
ground voltage.

G. Lighting Contactor

a) When specified, full voltage fused starter without overloads shall be provided for
lighting contactor for control of lighting transformer primary supplying high
pressure sodium lighting.

b) Lighting contactor shall be sized to applicable IEC Standard. The rating of

contactor for switching lighting transformers with 480V primaries, shall be as
follows:
Maximum Transformer Size
Minimum IEC Size of 3-Phase (kVA) 1-Phase (kVA)
Contactor
12A 3 3
32A 9 5
63A 15 10
160A 45 15

c) The lighting contactor unit shall include a Hand-Off-Auto selector switch and a
480-120 VAC secondary control power transformer with secondary fuse. The
CPT shall be sized to carry both the contactor coil and Purchasers remote
photoelectric cell.

H. Contactors for Resistive Heating Loads

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SINCOR
Project Title: SINCOR, C. A.
Sincor Document No:
Sincor Interface Code:
Sincor Document CLASS:
CA04-04-33-P-SP-005
0
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UPSTREAM SURFACE FACILITIES Page /File: 12/CA040433PSP005
Rev./Date: X3 / 26 Mayo 2006

a) When specified, full voltage magnetic starter shall be provided for resistive
heating loads to control heaters (other than infrared-lamp loads). The starter
shall not have overload relays.

b) Heating contactor shall be sized according to IEC Standard for switching

resistive heating loads other than infrared-lamp loads, as follows:

Heating Contactor Size

MINIMUM IEC Size of 3-Phase (kW) 1-Phase
Contactor (kW)
12A 20 12
32A 34 20
63A 68 40
160A 105 60

I. Anti-condensation heaters

120V AC thermostatically controlled space heaters, suitably rated to prevent

condensation shall be provided within each vertical section of the MCC, as per
Specification CA04-04-33-P-SP-001.

6. INCOMING FEEDER

If requested in the Data Sheet, an incoming on-load isolating switch housed in a separate and
suitably barriered cubicle, shall be provided (see Specification CA04-04-33-P-SP-001).

7. FEEDERS TO USERS

A. Circuit breakers for feeders to users and alike (sub-distribution panels, lighting panels,
etc.) shall be installed in completely barriered compartments, with hinged door on the
front.

B. Circuit breakers may be molded case plug-in or withdrawable type. Circuit breakers,
power and auxiliary terminals shall have a mechanical degree of protection not less
than IP 30 if in connected position. The required degree of protection may be achieved
with suitable protective cover.

C. Unless otherwise specified in the Data Sheet, more than one circuit breaker may be
housed in the same cubicle, provided that when one or more circuit breakers are
plugged-out or withdrawn, the incoming terminals are protected.

CA04-04-33-P-SP-005_X3 12 - 13
SINCOR
Project Title: SINCOR, C. A.
Sincor Document No:
Sincor Interface Code:
Sincor Document CLASS:
CA04-04-33-P-SP-005
0
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UPSTREAM SURFACE FACILITIES Page /File: 13/CA040433PSP005
Rev./Date: X3 / 26 Mayo 2006

8. INSTRUMENT TRANSFORMERS

The instrument transformers shall be as specified in Specification CA04-04-33-P-SP-001 and

Data Sheet.

9. BUSES

The construction and material of the buses shall be as specified in Specification CA04-04-33-
P-SP-001 and Data Sheet.

10. NAMEPLATES

Nameplates shall be as specified in Specification CA04-04-33-P-SP-001 and Data Sheet.

11. ACCESSORIES

Accessories shall be included as far as they are required to properly operate and maintain the
equipment. Additional available accessories shall be quoted as options. As a minimum, the
following must be provided:

Hand lever for operating the earthing switch, if required.

One portable earthing device, if required.

Special tools if required for installation and/or maintenance.

Two set of matching spray paint for touch-up.

12. TESTS

Type tests and routine test shall be performed as specified in Specification CA04-04-33-P-SP-
001 and Data Sheet.

13. DRAWINGS AND TECHNICAL DOCUMENTATION

Refer to Specification CA04-04-33-P-SP-001 for the drawings and technical documentation

requirements.

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