A== a. oor vwr- BASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV.:B PAGE 1 OF 38 SPECIFICATION FOR VARIABLE FREQUENCY DRIVE 8 ISSUED FOR APPROVAL 2019.45 ao ™ HD wr A ISSUED FOR APPROVAL 2016.7.25 cg iw zs sws REV. DESCRIPTION DATE PREP‘D CHK'D REVD APP'DBASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 2 OF 38 Revision History Revision A was completed on July 25, 2016. ‘The purpose of Revision B is updating some requirements based on the engineering & practice in Halfaya projects in the latest two years, and comments from PCH on Aug 16, 2018, The detail modification shall be as per revision marker in the documents. Major changes as followings: Chapter Revised to Local indicator display of soft starter shalll be mounted on panel door with 5.5 _ | extension cable for the easy access for fault reset, to monitor current parameters and to change display modes without switching OFF the power.BASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 3 OF 38 CONTENT 1.0 SCOPE 2.0 CODES, REGULATIONS, STANDARDS. 3.0 ENVIRONMENTAL CONDITIONS 4.0 DESIGN / MATERIAL / MANUFACTURE. 5.0 CONSTRUCTION REQUIREMENTS .. 60 P. ing. 7.0 VED MOTOR. 8.0 INSPECTION AND TESTS 9.0 DOCUMENTATION . 10.0 PREPARATION FOR SHIPMENT. 11.0 SUPPLIER'S RESPONSIBILITY AND GUARANTEES 12.0 SITE INSTALLATION ASSISTANCE, COMMISSIONING AND START-UP. 13.0 SPARE PARTS. 14.0 HEALTH, SAFETY AND ENVIRONMENTAL MANAGEMENT ... 15.0 VENDOR DRAWING REVIEW... 16.0 OPERATION CONSTRUCTION & MAINTENANCE MANUAL ....BASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 4 OF 38 1.0 14 12 13 SCOPE Purpose This specification together with the data sheets, defines the minimum requirements for the design, construction, painting, inspection, testing, documentation and preparation for shipment of variable frequency drive systems (VFDS) for Halfaya project surface facility. The VENDOR shall offer standard equipment to perform the duty stated in this specification and the Purchase Order. Any Variation of the VENDOR’s standard package from this specification must be stated by the VENDOR; otherwise it will be assumed that all equipment offered is in accordance with this specification Compliance with the requirements of this specification or any of the documents referred to herein shall not relieve the VENDOR of his responsibility to supply equipment of proper design, workmanship and materials conforming to good engineering practice to meet the specified conditions. Definitions OWNER + Petro China Intemational Iraq FZE Iraq Branch PROJECT : HALFAYA PROJECT SURFACE FACILITY EPCCONTRACTOR : _ Party which carries out all or part of the procurement, construction, commisioning and mangement of the PROJECT. EPC CONTRACTOR includes his approved MANUFACTURERS, SUPPLIERS, VENDORS and SUBCONTRACTORS, VENDOR : Manufacturers/Suppliers of goods/equipments SUBVENDOR : Part of Manufacturers/Suppliers of goods/equipments Vendor Shall : Indicates a mandatory requirement Should : Indicates a strong recommendation to comply with the requirements of this document Abbreviations BS EN : British Standards Euro Norms VDE + Verbrand Deutscher Elektrotechniker cP + Generator Control Panel ATS + Automatic Transfer Scheme AVR + Automatics Votage Regulator cT : Current TransformerBASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 5 OF 38 2.0 24 DC Direct Current EDG Emergency Diesel Generator iP : Ingress Protection Lv : Low Voltage MV Medium Voltage RTD Resistance Temperature Detector vt : Voltage Transformer ASL : Above Sea Level API : American Petroleum Institute pes : Distributed Control System EMC + Electro Magnetic compatibility HV : High Voltage lec + International Electro technical Commission IMcs Integrated Motor Control System IPF Instrumented Protective Function Iso International Standards Organisation LED + Light Emitting Diode MTBF : Mean Time between Failure MTTR + Mean Time to Repair PMS + Power Management System RT + Running up Time SPL + Sound Pressure Level THD + Total Harmonic Distortion ups + Uninterruptible Power Supply IEEE Institute of Electrical and Electronics Engineers VFD + Variable Frequency Drive CODES, REGULATIONS, STANDARDS. International Codes and Standards The following codes and standards, to the extent specified herein, form a part of this specification. When an edition date is not indicated for a code or standard, the latest edition in force at the time of VENDOR'S proposal submitted shall apply.BASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 6 OF 38 Instrument transformers — Part 2: Additional IEC 61869-2 requirements for current transformers Instrument transformers ~ Part 3: Additional IEC 61869-3 requirements for inductive voltage transformers IEC 60060 High voltage Test technique IEC 60076 Power Transformers IEC 60079-0 Explosive atmospheres ~ Part 0: Equipment ~ General requirements Explosive atmospheres — Part 14: Electrical IEC 60079-14 installations design, selection and erection Electrical insulation - Thermal evaluation and IEC 60085, designation IEC 60099 Surge Arrestors iE 60051 Direct Acting Indicating Analogue Electrical Measuring Instruments and Their Accessories, Basic and safety principles for_man-machine IEC 60073, interface, marking and identification — Coding principles for indicators and actuators ‘Semiconductor converters - General requirements IEC 0146-1 and line commutated converters ‘Measuring relays and protection equipment — IEC 60255-1 Part 1: Common requirements IEC 60282 High-Voltage Fuses IEC 60269 Low-Voltage Fuses Degrees of Protection Provided By Enclosures IEC 60529 (IP Code) IEC 60617-DB Graphical Symbols for Diagrams IEC 61000-4 Electromagnetic Compatibility ‘Adustable speed electrical power drive systems - lec 61800-3 Pat 3: EMC requirements and specific test methodsBASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 7 OF 38 IEC 6271-103 High-voltage switchgear and controlgear - Part 103: Switches for rated voltages above 1 KV up to and including 52 kV IEC 62271-200 High-vottage switchgear and controlgear Part 200: AC metal-enclosed switchgear and controlgear for rated voltages above 1 KV and up to and including 52kV IEC 61439 Low Voltage switchgear and control gear assemblies EC 61378-1 Converter transformers — Part 1: Transformers for industrial applications IEC 61378-3 Converter transformers - Part 3: Application guide IEC 61947 Electronic Projection - Measurement and Documentation of Key Performance Criteria IEC 60445 Basic and safety principles for man-machine interface, marking and identification — Identification of | equipment __ terminals, conductor terminations and conductors IEC 61554 Pane! Mounted Equipment - Electrical Measuring Instruments - Dimensions for Panel Mounting. IEC 61800-4 General requirements - Rating specifications for AC. power drive systems above 1000V A.C. and not exceeding 35kV IEC 61800-5-1 ‘Adustable speed electrical power drive systems - Part 5-1: Safety requirements - Electrical, thermal and energy. ISO 9001:2000 Quality Management Systems-Requirements ISO 9004:2000 Quality Management Systems-Guidelines for performance improvements ISO 10816-1 Mechanical vibration - Evaluation of machine vibration by measurements on non-rotating parts - Part 1: General guidelines IEEE 519 Recommended Practices and Requirements for Harmonic Control in Electrical Power SystemsBASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 8 OF 38 22 23 24 Order of Precedence ‘The order of precedence of the engineering document shall be as follows: + Laws and Regulations in Iraq; ‘+ Electrical Design Basis; + Data Sheets; ‘+ Project Specifications; ‘+ Material Requisition; ‘+ OWNER’s Specifications (If any). International Codes and Standards in the event of any conflict of data or requirements in any of the above documents, it is the Vendor's responsibility to consult the OWNER / EPC CONTRACTOR and a ruling, in writing, shall be obtained before any work is started ‘Specification Deviations / Concession Control. Specification Deviations / Concession Contral Deviations from this specification are only acceptable where the VENDOR has listed in his quotation the requirements he cannot, or does not wish to comply with and the OWNER / EPC CONTRACTOR has accepted in writing the deviations before the order is placed. Any technical deviations to the Purchase Order and its attachments including, but not limited to, the Data Sheets and Narrative Specifications shall be sought by the VENDOR only through Concession Request Format. Concession requests require OWNER / EPC CONTRACTOR review/approval, prior to the proposed technical changes being implemented. Technical changes implemented prior to OWNER / EPC CONTRACTOR approval are subject to rejection Language and Units of Measurements The governing language of the Contract shall be English language. All notices, correspondence, information, literature, data, manuals and other documents required under the Contract shall be in the English language. Technical units, quantities, etc. shall be expressed, used and abbreviated according to the SI system. Preferred units of measure are as follows: Flow Rate :mi/hr, MMSCFD (gas), BPD (condensate), BWPD (Water) Power, Duty kw Area :m2 Length metre (m), km, mm Pressure + Bar (Q), Bar (a), KPa (g) Temperature 2cBASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 9 OF 38 Volume m3 Weight 2 Kg 3.0 ENVIRONMENTAL CONDITIONS Item’ Unit Value Altitude mASL 05-6" ‘Atmospheric Pressure kPa 102 Max. Temp. °c 55 Dry Bulb Temp. °C 42.2 (GPSA 11-3b) Max. Metal temp. by sun shine _| °C 80 Min. Temp. °C 2 Max. Speed Wind m/ mis 40 Prevailing Direction Wind (winter) NW-SE Prevailing Direction Wind (summer | NW-SE Max. Relative Humidity 80% Min. Relative Humidity 25% Rainfall mmia 177.4 4-Hour Rainfall mmia 4 Temp. °c 15 in winter (1.2-1.6 m) 33.6 in summer (1m) Seismic Zone 28 Evaporation Rate mmia 3054.4 Notes: * Parts of the data above are from site survey data of Phase 1, Phase 2 of HALFAYAH project surface facility. 4.0 DESIGN / MATERIAL / MANUFACTURE. 44 General The VFDS includes VED Rectifier, Converter, Drive Input and Drive Output, Transformers, Interconnecting Power Cables, Drive Cooling Equipment, Control and ‘Synchronization Devices, Harmonics Filters, any other accessories required for safe ‘commissioning and operation of the Entire Drive System The equipment shall be complete in all respect as defined in this Specification, Datasheet & the Material Requisition.BASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 10 OF 38 42 The order for a VFD may be placed direct with a MANUFACTURER or through the MANUFACTURER of the driven equipment, both of whom shall be approved by the COMPANY. In the latter case the MANUFACTURER of the driven equipment has the responsibility for the correct operation to specification of the combination of VFD,VFD Transformer and driven equipment. ‘The MANUFACTURER of the VFD shall have ample experience in the design and application of those systems, power factor correction and harmonics filters. ‘The following shall be provided by the MANUFACTURER: © Calculated rotor responses; = Ramp times; ‘+ Transient air gap torques with their duration in the event of 2 and 3 phase short Circuits at the motor terminals; ‘* For running up and continuous operation, data on all machine air gap torques including integer and non-integer harmonic torques in amplitude and frequency, also stating the assumptions on ratings of de-link components; ‘© Lubrication requirements. Furthermore the responsible MANUFACTURER shall be capable of: + Performing the necessary torsional and lateral vibration analyses; ‘+ Performing the required studies of the total train (drive system and driven equipment) and acting as a suitable counterpart to the MANUFACTURER of the driven equipment (and gearbox if included) to ensure good overall coordination; ‘* Performing the necessary electricel system studies. The final result of these studies shall be acceptable to all parties involved. If specified in the data sheet, the MANUFACTURER shall quote a torsional vibration analysis as a separate item. The COMPANY may request this study to be performed in addition to that performed by the driven equipment MANUFACTURER. In such event, the results shall be acceptable to all parties involved. The COMPANY may request a third party to investigate the analysis on his behalf. For the technical evaluation of the quctations at least all data specified in the datasheet shall be available. Quotations without all these data shall not be accepted. If deemed necessary by any of the parties involved, a pre-ordering meeting shall be arranged to define clearly the overall scope of supply, individual responsibilities and test methods. Basic Requiroments of VFDs The equipment shall be capable for operation on a continuous basis of 24 hours per day, for a period of at least 6 years without maintenance. The expected life time of the VFDS shall be 25 years.BASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 11 OF 38 43 The converter shall not be tripped by Voltage dips of 15% due to starting of irrelevant electric motors. ‘Switching the power supply to the converter under ful-load condition “off and not trip the converter. Exposed parts within the equipment which have to be accessible during normal operation of the VFDS for measuring, adjusting, resetting etc. shall when the door is open have an enclosure to a degree of protection of at least IP20. The materials shall be selected to prevent contact corrosion. All screws, bolts and nuts. shall be corrosion-resistant. Each enclosure shall have a thermostatically controlled anti-condensation heater. The heater circuit of each cubicle shall be separately protected and switched by 2 pole miniature circuit breaker. Interconnection cabling between separate enclosures shall be designed and supplied by the supplier. Cables shall be steel wire armored. Measures shall be taken to ensure that HV compartments cannot be opened unless all ‘components in the compartment are clectrically dead and carthed. Products that are hazardous or toxic to environment or that are considered potential carcinogens shall not be used. The VFDS shall be an autonomous system. No other supplies shall be required for auxiliaries other than the main power supply and control voltages as indicated in the data sheet. shall Identical components, sub-assemblies and modules shall be used to allow interchangeability, minimize spare parts and simplify servicing and repair. Design requirements of VFD The VFDS shall be capable of withstanding the thermal and dynamic stresses and transient mechanical torques such as those resulting from a short circuit. Any damage resulting from such a short circuit or internal fault shall be confined to the component concemed. The motor/driven equipment shall be able to withstand the transient torques developed during short circuit conditions The air cooling VFD shall include minimum of an inputisolation multi winding transformer, 12-pulse input converter (need to be validated on actual situation), a direct current link, output converter, protection equipment, high voltage electric motor, control/monitoring panel, harmonic fiter. and/or power factor correction (if required), and other accessories. Drives shall utilize direct air cooling for power components. Drives and HV motors shall be purchased as a package from one VENDOR. The VFDS shall be suitable for the load characteristics and the operational duty of the driven equipment. It shall be suitable for min 2 consecutive Starts, if not otherwise specified in datasheet. \VFD-motor packages and systems (including isolation transformers and filters) shall be specified, designed and configured to limit the voltage and current harmonic distortion to levels below those defined in IEEE519, IEC 61000-3-2, and IEC 61000-3-6.BASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 12 OF 38 5.0 54 The design of the VFD shall meet the immunity levels of IEC 6180-3. CONSTRUCTION REQUIREMENTS \VFDS shall be a line-fed AC to AC conversion system consisting of facilities required to ‘operate the electric motors at variable speeds on a variable voltage or current and frequency. In general the VFDS shall consist of: ‘© Supply transformer to the converter. «Converter. = Reactor(s). = Bypass circuit. © Cooling equipment. Each converter should be basically corsisting of: © Circuit breaker (lockable In “off” position). = Contactor. * Harmonic filter and power factor correction equipment. © Control! and auxiliary equipment supply and distribution system © Control, triggering and system control equipment. Protection, supervision and alarm equipment and measuring / testing facilites, «Rectifier. = Clink. = PWM (pulse width modulated) Inverter. * Earthing switches at both input and output of HV converters Service condi Voltage and Frequency variations The voltage and frequency variations shall be limited to the following values: © Voltage + 10 %. © Frequency + 5%. * Combined frequency and voltage variations shal be in accordance wth IEC 60034- The VFDS shall be suitable for operation on a supply system with a short circuit rating not less than 10 times the kVA rating of the VFDS at its terminals.BASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 13 OF 38 52 Vacuum Load Break Switch -Fuse Combination 5.2.1 General ‘The Converter transformer shall meet the requirements of and be tested in accordance with specification for Power & Distribution Transformer and Neutral Earthing Resistor, IEC 61378-1, IEC 61378-3 & IEC 60146-1. The transformer of the VFDS will normally be mounted close to the substation if it would be put outside. Transformer and auxiliaries shall be IP54 while terminal boxes shall be IP55. Dry type transformers may also be offered if fully complying with the requirements of this specification and after approval by COMPANY. Thermal class F/H insulating material shall be used for dry type transformer. 5.2.2 Temperature detector The transformer shall be equipped with 2 embedded temperature detectors per phase. For oil-filled transformers; the embedded temperature detectors may be omitted. However, a Buchholz relay chall be installed on the transformer. An overload of the transformer shall trip the VEDS and give an indicating alarm on the converter. The trip temperature will be set to 130°C for dry-type transformers. 5.2.3. Impedance The impedance of transformers with two secondary windings for 12 pulse systems shall be selected to ensure equal load/ current sharing between the two secondary transformer windings, the converters and the motor windings under all operational conditions including starting and restarting. 5.2.4 Harmonics The converter transformer shall be suitable for operation with the non-sinusoidal current wave shapes and DC components under normal and abnormal (e.g. short circuits) conditions of the VFDS without exceeding its temperature or other limits under the conditions of this specification & specifically designed to meet the requirements of the VFD. 5.25 Noise The noise limits shall be met at any load condition within the operational speed range of the VFDS. 5.2.6 Rating plate The rating plates shall be made of stainless steel and be fixed to a non-removable part of the frame. Rating plates shall in general give the following data, as far as possible actually measured. The values given shall be related to the maximum operating temperature and the most arduous site conditions. Rating Plate Mounted on the Transformer Converter Transformer Data: Manufacturer's nameBASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 14 OF 38 5.3 Manufacturer's serial number and year of manufacture ‘+ CONTRACTOR'S purchase order number ‘+ Type of transformer and mass ‘+ The degree of protection of the transformer ‘+ Rated transformer output and rated fire angle of ine commutated converter * Rated no-load voltage ‘= Rated currents © Rated frequency ‘+ Number of phases = Vector groups ‘+ Impedance and reference power ‘© Type of cooling ‘+ Class of temperature for dry type transformer and temperature rise ‘+ Connection diagram ‘+ Insulation levels © Total mass ‘* Transportation mass = Untanking mass ‘© Mass of insulation oil © Insulation liquid ‘+ Details regarding tapings. ‘+ Equipment tag number Reactors The converter reactor(s) shall meet the requirements of and be tested in accordance with the IEC 60146-1. Converter reactor(s) shall be suitable for operation with the non-sinusoidal current wave shapes and DC components under all operational conditions of the VFDS without ‘exceeding its temperature or other limits under the conditions of this specification. 5.3.1 Harmonics Converter reactor(s) shall be suitable for operation with the non-sinusoidal current wave shapes and DC components under all operational conditions of the VFD without exceeding its temperature or other limits under the conditions of this specification.BASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 15 OF 38 532 Protection Dry type reactors shall have temperature detectors and alarm and trip features. Cilfilled reactors shall have a high oil temperature alarm and trip, and in addition, reactors with a conservator shall have a Buchholz relay installed. The reactor(s) shall be equipped with 2 embedded temperature detectors. ‘An overload of the reactor(s) shall trip the VEDS and give an indicating alarm on the converter. 5.3.3 Noise The maximum sound pressure level (SPL) at a distance of 0.3m shall not exceed the value given by the following equation: SPL = 45 + 8 logi0 PdB(A), where Ps stated in kVA. The noise limits shall be met at any load condition within the operational speed range. 534 Rating plate The rating plate chall be made of corrosion recietant metal and be fixed to a non removable part of the frame. Rating plates shall in general give the following data, as far as possible actually measured. The values given shall be related to the maximum operating temperature and the most arduous site conditions. In addition to the data specified in the following (where applicable) shall be included: + Manufacturer's name Manufacturer's serial number and year of manufacture ‘+ CONTRACTOR'S purchase order number Converter Reactor Data: © Type of reactor and mass ‘©The degree of protection of the reactor © Rated output + Rated voltage = Rated current ‘© Type of cooling ‘+ Class of Insulation for dry type reactors, and temperature rise ‘+ Insulation level © Total mass ‘+ Transportable mass © Untanking massBASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 16 OF 38 54 ‘= Mass of insulation oil = Type of Insulation liquid ‘+ Percent impedance; ‘+ Equipment tag number 535 Location ‘The MANUFACTURER shall give the requirements regarding the location of the reactors) relative to the converter panels. If air-cored reactors are offered, the extent of the iron-free zone around the reactor(s) shall be stated in the quotation for initial layout. ‘The MANUFACTURER shall also provide data on the preferred cable specification. NOTE: This information shall enable the COMPANY to lay out the building containing the converter and reactor(s). Converter The rectifier shall be a fully controlled three-phase rectifier bridge circuit ‘One DC link inductor should be supplied with each 12 pulse channel electrically connect to the output of the line converter and the input of the load inverter to maintain continuous current between them to maintain continuous current over the operating range and to decouple the rectifier and inverter. The inductor should be indoor air core, dry type with class H insulation system. It should be equipped with over temperature sensor embedded in the winding, Inverters shall be voltage source inverters (i.e. the DC link connected to the inverter input terminal shall be voltage source) ‘A DC voltage source shall be made by connecting a capacitor to the output of the rectifier. Voltage source inverters the output voltage and output frequency shall be controlled together (Vif = constant). The motor stator frequency (speed) is governed through self- ‘commutated load side converter (inverter). Control of stator voltage as a frequency - dependent variable shall be through controlled line commutated converter (rectifier) or pulse-width modulation of inverter output. The inverter shall be PWM (pulse width modulated) and shall utilize Integrated Gate Bipolar Transistor (IGBT). ‘A motor filter capacitor shall be supplied with the converter to reduce motor harmonics caused by the output of the inverter especially at high speeds to minimize motor heating and to supply reactive power to the induction motor and inverter. The capacitors shall be capable to handle rated converter overloads without injury. The harmonics filters shall be provided at the supply side such that the maximum allowable voltage and current distortion are as follows: '* Voltage distortion shall not exceed 2%.BASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 17 OF 38 ‘+ Current distortion shall not exceed 5%. The following features shall be available for motor filter capacitor: ‘* The filter capacitor shall be rated for ambient temperature. ©The capacitors shall be mechanically rated to withstand the available short circuit current. ‘* Protection and annunciation of failed filter capacitor shall be provided. + Non-flammable dielectric material and liquids shall be used. Converter components shall be accessible from the front of the cubicle. All control devices, switches, circuit breakers, indicating lights and measurements shall be mounted on the hinged door of cubicle panel. The converter control and power electronic equipment shall be plug in or drawout type as possible. In general, each converter should comprise: Isolation switch (lockable in off” pasilion) Contactor/circult breaker Harmonic fiter and power factor correction equipment Control and auxiliary equipment supply and distribution system Control, triggering and system control equipment Protection, supervision and alarm equipment and measuring/testing facilities Rectifier DC link Invertor Earthing switches at both input and output of HV converters, Cooling equipment Isolation switch (lockable in ,off* position) Contactor/circuit breaker Harmonic filter and power factor correction equipment Control and auxiliary equipment supply and distribution system Control, triggering and system control equipment £. Protection, supervision and alarm equipment and measuring/testing facilities 5.4.1. Noise The converter shall meet the sound pressure limit of 81 dB(A), with ref. to 20 uPa, at any location 1m distant from the converter under any load and/or frequency condition within the operational speed range of the VFDS. If more stringent limits are required this will be indicated on the requisition. rxyereaoge eeaegpatBASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 18 OF 38 5.5 5.4.2 Marking of the Converter Components Converter components, such as PC boards, thyristors, diodes, switching devices, protection relays, Instruments, instrument transformers, fuses and fuse holders, shall be identified in accordance with the schematic diagrams by means of permanent labels. In addition, all components shall be marked according to VENDOR'S standard with their ratings and all other essential data as required, following IEC recommendations: 9g. Manufacturer's name or trade mark and type designation h. Rated main and auxiliary operational voltages, frequency and number of phases i. Rated currents or rated powers J Accuracy class and accuracy limit factor, e.g. for instruments and instrument transformers. ‘On withdraw able type units, identification labels shall be mounted on both the fixed and withdrawable parts. 5.4.3 Converter Cabinets The converter cabinet shall be sclf supporting and suitable for floor/wall mounting. The maximum height of the cabinet shall not exceed 2200 mm excluding fans. fan hoods or ducts and the Maximum door width shall be 800 mm. Indoor converter assemblies shall have a degree of protection of at least IP 42. Anti-condensation heaters shall have overcurrent and residual current protection and shall not be supplied from a UPS source. 5.4.4 Cooling of the Converter Cooling methods accepted for converter cooling are: Direct cooling, e.g. Natural ventilated air-cooled ‘= Forced ventilated air cooled ‘System control, Protection & Alarm 5.5.1 General The VFDS shall be controlled by fully digital microprocessor-based system. ‘The microprocessor system shall be provided with the ability to modify and update system constants, settings and logic functions. ‘The microprocessor system shall be protected against loss of supply voltage and faulty signals corrupting the information. The system shall be suitable for local and remote control and shall have a readout unit for the status indication and set values. Internal faults shall trip the converter circuit breaker. A manual reset shall be provided for restarting.BASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 19 OF 38 The diagnostic and protection system shall monitor and protect the complete VFDS including motor protection. The fault diagnostic and indication logic shall be equipped with a memory function to retain information for 4 days regarding the cause of tripping of the frequency converter. The converter shall have setting devices to a dust limits such as current, acceleration Time, minimum & maximum frequency, ete. All mA signals and any other regulation or control circuit shall be galvanically separated from any other system. The closing, operating and opening of the circuit breaker feeding the VFDS shall be via volt-free contacts from the converter. ‘Any provisions seems necessary to be added to the circuit breaker has to be stated by the VFDS supplier with the quotation. The VFDS will be either speed or torque or power controlled in accordance with the requirement stated on data sheet and/or material requisition. ‘A combination of the control functions is alse possible. Unless otherwise specified on data sheet, the frequency converter will be controlled by the following signals: = 0-420 mA reference signal (supplied by Purchaser), © Ready to start signal (interposing "on" signal) ‘+ External potential free contact will be given if the VFDS is allowed to be started. ‘+ Stop signal (interposing “off” signal) ‘+ External potential free contact is given by an emergency condition of the driven equipment or the driven equipment or the process. ‘= Remote stop signal ‘+ The stop signal given from the stop push button located near the motor shall trip the MV contactor/motor circuit breaker. The relationship between the speed, torque or power and the reference signal within the ‘operational speed shall be linear. A reference signal 4 mA shall correspond with the minimum operational speed or torque or power and a reference signal of 20 mA shall correspond with the maximum operational speed or torque or power of the VFDS. Loss of the 4-20 mA reference signals shall normally result in operation of the VFDS at ‘minimum operational speed, torque or power. ‘The VFDS shall be equipped with an automatic restart facility which will restart the system in case of voltage dips over 20% or power interruptions shorter than an adjustable time interval of up to 1 minute. Restart will only take place if the line voltage recovers to over 90% of its nominal value. It shall also be possible to block the automatic restartBASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 20 OF 38 A Upon restart the converter shall be capable to synchronize on a rotating motor, and develop full acceleration torque within 10 seconds. Local indicator display of VFD shall be mounted on panel door with extension cable for the easy access for fault reset, to monitor current parameters and to change display modes without switching OFF the power. The system shall be equipped with "data logging" facility to dedicate the following: = Date. + Time. = "Alarm" messages. + "Ready" messages. + "Fault" messages ‘+ Source KVA / Source power factor. * Source current / voltage. ‘+ Source fring angle. © DC Link voltage / current. ‘+ Motor speed / current / voltage. = Drive horsepower / kilowatts. ‘+ Inverter power factor. © Speed command. ‘= Inverter firing angle. © Torque limit. = Current limit, The information will be retained for a period of min. 4 days after interruption of the power supply to the VEDS (only applicable for HV fed VFDS), The system shall be equipped with "fault history" facility to store latest fault events, up to 10 events. The control system shall be immune from spikes and voltage distortion due to operational and/or fault conditions within the VFDS Main control circuits shall be protected by miniature circuit breakers. Branch control circuits shall be also protected by miniature circuit breakers. Facilities shall be provided to give indication and alarm in the event of a tripped circuit. Signal loops shall be fail safe. Protection circuits shall operate according to the operating current principle. All service adjustments that may be required in the field shall be possible from the front of the equipment. Measuring and test point shall be front accessible.BASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 21 OF 38 5.5.2 Protection The system shall be equipped with comprehensive network of protective systems to prevent damage to critical components. The following fault conditions shall shut down the converter as a minimum: = AC supply over voltage. © AC supply under voltage + AC supply over current. ‘+ AC supply reverse phase sequence. ‘+ Internal short circuit. ‘+ Converter current protection. * DC link over-voitage. © Loss of control voltage. + — Earth fault main circuit. + Earth fault secondary circuit. = Over speed. + Under speed. ‘+ Microprocessor failure. + Load over voltage * Single-phase motor side protection. ‘+ Motor protection faut © Low input signal. ‘© Power electronics and enclosure over temperature. = Failures of auxiliaries All motor protection devices as shown on the one line diagram shalll be included in the VFDS unless otherwise specified. The extemal rip signal shall be direct acting 553. Alarms Alarms and faults shall be annunciated on the front panel Each alarm or shutdown shall be associated by horn signal and flashing lamps. The fault will be acknowledged by push button, the acknowledgement will stop sonar signal. Action of the annunciators shall be first up, with reset and test facilities. First fault alarm shall be detected after shutdown.BASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 22 OF 38 The following alarms shall be monitored: ‘+ Failure of auxiliaries and with identification of the failing unit. ‘+ Under voltage incoming side. ‘* Motor current protection. ‘+ 5% measured value deviation from the set point. * Voltage/Frequency ratio incorrect. ‘+ Missing run or start permissive. © Fuses failure. ‘+ Microprocessor problem. © Link inductor alarm, ‘+ Input/output addressing problem. ‘+ Loss of reference signal ‘+ Loss of speed control. ‘+ IGBT problem. ‘+ IGBT inverter over current. '* Motor over temperature. ‘* High coolant temperature. = Low coolant pressure. = Low coolant level. ‘* Failures of auxiliaries together with identification of the failing unit Adjustable time delays shall be provided for each alarm function to prevent spurious alarm signals being generated during transitory conditions. Alarm signals shall be combined to provide two "common alarm" signals wired to a terminal strip for remote indication. Alarms associated with the input supply shall be inhibited if the mains breaker is open. Volt free contacts for remote signaling and alarms shall have the following ratings: 220 & 110 DC - 5 A continuous. © 48& 24DC-3A continuous. All alarms shall be displayed on the VFDS front. 5.5.4 Measurements Measurements shall be provided as minimum as follows: © Input voltage/current/frequency. ‘© Output voltage/current/frequency.BASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 23 OF 38 + Output torque. = Output power. + Speed. 5.5.5 Communication The system shall be able to communicate with the EICS/DCS by means of a standard serial communication interface Modbus RTU RS-485. 5.5.6 Indicating Lights For each VFDS, the following indicating lights shall be provided as a minimum: ‘+ Mains "ON" Red light. ‘+ Mains failure amber light. ‘+ Allcircuit breaker(s) openiclosed/fault Green/Red/Amber lights * Converter ON/OFF Green/Red lights. = Ready for operation Red light. + Motor Running Green light. All indications shall be mounted on the VFDS cubicle front. Lamps shall be accessible from the front of the cubicle to facilitate lamp replacement. Indicating lights by means of light-emiting diodes (LED's) are acceptable while the use of filament lamps is not accepted Lights shall be provided with lamp test facilities. Failure of an indicating Lamp or an LED shall not cause the system maloperation. 55.7 Push Botton&Switches The controller shall have start and stop push-buttons to start the unit or to stop in addition to the possibility to start or stop the unit via the pad start/stop function. The controller shall have an emergency stop button, to shut the controller down instantly whenever needed. This button function supersedes any other command, ‘The controller shall have local-ot-remcte switches to define the operation either from the door mounted device or key pad or Via a remote control signal. In the off position, the operation cannot be started. In addition, the following push buttons or switches shall be provided for each VFDS: ‘+ Status request push button ‘+ Reset push button * Speed adjust potentiometerBASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 24 OF 38 56 57 58 Bypass circuit ‘A bypass circuit shall be provided so that a line supply of the squirrel cage motor is possible. ‘The system shall have automatic changeover to bypass upon fault. Cooling requirements Cooling method shall conform to IEC 60146-1-1 and as specified on the data sheet cooling air openings shall only be located on front or on top of the panels. Forced ventilation shall include the necessary air filters, fans and ducting. Where forced ventilation is provided, failure of a single fan unit shall not cause the converter to shutdown at full load. Redundant fans shall be provided. An alarm shall be given in the event of a fan failure. Replacement of faulty fan can be achieved without converter shutdown. Cooling fan motors shall be protected against overload and short circuit The cooling method either direct (natural or forced ventilated air cooled) or indirect (air to air or air to liquid, etc.) shall be stated in manufacturer quotation for Purchaser approval. Cooling equipment expected life time to be as per VFDS iife time. Performance requirements of VFDs In general the VEDS shall be designed such that the torque/speed characteristics of the driven equipment are met without overrating. The VEDS shall be suitable for the load characteristics and the operational duty of the driven equipment. ‘The VFDS shall be capable of developing at least the following torques: a) Constant torque Drives: = During starting & restarting 150% maximum rated torque for 10 seconds. + After starting & restarting 120% maximum rated torque for 60 seconds. and during reacceleration © Continuously The maximum torques according the Maximum rated torque curve. b) Other Drives: ‘© During starting & restarting 120% maximum rated torque for 10 seconds. = Affer starting & restarting 110% maximum rated torque for 60 seconds. and during reacceleration = Continuously ‘The maximum torques according the maximum rated torque curveBASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 25 OF 38 59 5.10 The VFDS shall meet above torque requirements at any line voltage between 95% and 110% of the nominal line voltage. Wiring All internal wiring shall be flexible standard copper conductor, PVC or XLPE insulated, 600/1000V, flame retardant. Minimum wire size for control wiring shall be 1.5 mm2 and for power and current transformer wiring 2.5 mm2. All wiring shall be neatly arranged end clipped in groups and protected by flexible conduit or channels with covers. Each conductor and its terminations are to be identified and marked with numbered and/or lettered ferrules in accordance with the related wiring diagram. As far as practicable, signal conductors shall be segregated from power wiring and AC wiring shall be segregated from DC wiring Wiring to equipment mounted on doors shall be carried out through flexible conduits, or spiral wrap. Cable Terminations All cables shall enter the converter from below. Cable entries, cable clamping, earthing and supporting devices shall be provided. These shall be suitable to accept the type, size and number of cables specified on the data sheet. All power cables shall have compression type lug connections. ‘Small wiring terminations for control connections shall be of the non-loosening spring loaded type shall be readily accessible with a minimum of 150 mm between adjacent rows. Each shall be adequate to terminate 2 X 2.5 mm2 conductors. Not more than one wire shall be connected to any one terminal All power connections shall be busbars connection provided with stud type terminals complete with nut and locknuts. Positioning of cable termination shall avoid obstruction of other cable terminations. All terminal blocks shall be shrouded or provided with transparent covers. Circuits and terminals operating at different voltages or performing different functions shall be segregated by barriers. At least 20% spare terminals shall be provided in each control and indication terminal block. Cable gland plates shall be readily removable for the drilling and fitting of glands. Gland plates shall be made from metallic non-magnetic materials. Cable glands, lugs and heat shrinkable termination kits shall be supplied by others unless otherwise specified on data sheet.BASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 26 OF 38 5.11 5.12 Power connections shall be of the disconnectable cable termination system. Terminations system shall be of sufficient size to adequately terminate the specified cables/conductor type or size. Wiring and terminals shall be identified in accordance with the related wiring diagrams. In view of the maximum acceptable voltage drop, a large number of cables in the same trench and the short circuit rating of the system, the prescribed cable size or the number of cables can be twice that considered normal by supplier. Consequently a larger space for cable connection than standard shall be required. Earthing Converter cubicles shall be equipped with an earthing bar of high conductivity copper. The earthing bar shall be of adequate cross-sectional area and mechanical strength to allow convenient connection of all cable earthing connectors and an external earthing cable sized 70 mm2. All metallic, non-current carrying par's shall be bonded together and to the copper ground bar. All components shall be bonded together and to the cubicle ground bar. All gland plates shall be provided with ground straps to provide a positive connection between the gland plate and cubicle ground. Nameplates Nameplates shall be provided to identify all circuits entering or leaving the equipment. These shall be attached to the external surfaces of the equipment. Nameplates minimum size shall be 125 mm by 30 mm. Nameplates shall also be provided to identify the components and wiring of the control and protective circuits. Nameplates shall be sized according to the space available for ‘mounting, Compartments which contain accessisle permanently live terminals shall be provided with warning signs, advising personnel of this fact. Nameplates shall be laminated plastic with engraved black letters on white background. Nameplates shall be attached using a minimum of two (2) stainless steel screws per plate. Adhesive type nameplates are not acceptable. Inscriptions shall be in the English language. Main data nameplates shall be affixed in a prominent position on each unit giving the following information: ‘+ Manufacturer's name, type, model and serial number. © Unit designation. ‘+ System voltage, phases, wires and frequency. © Rated fault currentBASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 27 OF 38 = Switch ratings = Year of manufacture 5.13 Electrical Immunity All Equipment shall be able to generally withstand the impact of the imposed electrical tests as defined in referenced IEC. 5.14 Disturbance Imunity The entire system shall be suitably screened to optimize electromagnetic compatibility (EMC), The whole equipment shall be type tested in accordance with IEC 61000 part 4, level 3 - typical industrial environments, as detailed below: IEC 61000-4-2- Electrostatic Discharge - level 3 - 8 KV air discharge. IEC 61000-4-3-Radiated Electromagnetic Field (RFI) - level 3-10 Vim. IEC 61000-4-4-Electrical Fast Transient - level 3 - 4 kV common mode. IEC 61000-4-5-Surge - 2 kV line - earth and 1 kV line — line. ‘The manufacturer shall provide type test certificates from a recognized testing authority to verify that the whole equipment is effectively screened against EMC in line with the applicable IEC standards. 6.0 PAINTING The equipment shall be thoroughly cleaned free of scale, sand, rust and grease. The ‘mountings and other extemal parts shall be given one priming coat of paint and two top coats and otherwise made corrosion resisting. The colour finish shall be as specified in datasheet The method of surface preparation and the paint system to be used shall be agreed by the purchaser during quotation and before painting is started. 7.0 VFD MOTOR The motor shall meet all the requirements of this specification and Specification for Electric Motors Rated above 185kW, Doc no- HFY3-CPF2-ELE-SP-01014. This section amends following sections of the above mentioned Specification. In case of conflicting requirements the VENDOR must obtain a clarification from CONTRACTOR. 7.1.1 Amendment to Sub Section 4.4- Methods of Cooling: “Other methods of cooling (e.g. IC6A1A1 OR IC6A1A6) are also acceptable with prior approval from COMPANY. In case of IC6A1A6, 2x100 % or 3x50 % redundancy shall be offered on cooling fans.” 7.1.2. Amendments to Section 5.0. - STARTING, RE-STARTING & REACCELARATION.BASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 28 OF 38 ‘+ Sub Sections 5.2 to 5.11 shall not be applicable for VFDS driven Motor However following note shall be applicable at the end of each sub section 5.2 to 5.11 “Variable frequency drive motors shall comply with IEC 60034-17 and HFY-GEN-ELE- ‘$PC-0023 and shall be designed for VFDS system” ‘+ Sub Section 5.18. — Winding insulations ‘Add the following under this section: “Phase identification (UVW or RYB) shall be provided on winding leads in terminal box.” ‘© sub Section 5.19-Terminal Box ‘Add the following at the end of the section: “For large motors with heavy terminal box and cover, lifting hook shall be provided on both sides of terminal box as well as the cover. Contractor shall provide the information on number and size of power cables to manufacturer so that the terminal boxes are be made suitable for the application Additional gland hole with properly certified plug shall be provided on the motor terminal bux.” * Sub Section 5.22 Protections ‘Add the following note before last paragraph: “In case of VFDS driven motors, differential protection for motor shall not be applicable.” “In case of VFD driven motors, the Partial Discharge coupler shall not be installed, since the same shall not work properly with variable frequency.” Sub Section 5.21.2 fans ‘Add the following note at the end of the section In case of shaft-mounted fans, the rotor would be balanced without the fans and then again after the fans are fitted by fitting balance weights to the fans. 8.0 INSPECTION AND TESTS 81 General ‘The MANUFACTURER shall perform during the production of the VED all activities, functions and tests to prove that the requirements of this specification are met. Before leaving the MANUFACTURER'S works each VFD shall be inspected and tested, and the results recorded in test reports. ‘Components installed within the assembly shall be type tested in accordance with the applicable IEC standards (eg. IEC 60947). Certificates obtained from the MANUFACTURERS of the components shall be made available at the request of the COMPANY. Equipment to be installed in a hazardous area in accordance with IEC 60079 shall be certified by a ‘Notified Body. Copies of certificates shall be made available,BASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 29 OF 38 If the MANUFACTURER's normal test arrangements are not applicable or the MANUFACTURER is unable to perform the specific tests according to design specifications, then the tests to be performed shall be subject to agreement between the MANUFACTURER and the COMPANY before the order is placed. For example, 60 Hz equipment may be tested at 50 Hz, or vice versa, or tested under reduced load conditions. 8.1.1 Factory Acceptance Tests. In general, all testing shall be carried out fully in accordance with this specification. The MANUFACTURER'S standard test protocol shall be acceptable provided it is no less stringent than specified in this specification. As part of the quotation, the MANUFACTURER shall provide a detailed test protocol of all the routine and special tests that will be carried out. Whether the COMPANY or his nominee will inspect the equipment and witness the required tests shall be indicated in the data sheet and confirmed or waived at the time the equipment is offered for final inspection. Notification thereof shall reach the COMPANY at least two working weeks before the testing is scheduled The VFD offered for final inspection shall be complete and ready to be prepared for ‘shipment. 8.1.2. Performance Tests The performance test shall be made on at least one VFD of a group of identical systems to be supplied. The MANUFACTURER shall state in the quotation the availability of test data of identical VFD, including auxiliaries, covering all performance test requirements, with protocol number and test date. This test protocol may be acceptable instead, if submitted well in advance of the delivery date of the VFD and if approved by the COMPANY. After the successful performance tests of the individual items as applicable, e.g. motor, transformer in accordance with the respective specifications, the VFD shall be lined up for a complete test with all equipment included in the order, ¢.g. unit transformer, motor, converter and auxiliaries. Unless otherwise agreed with the COMPANY, the performance test shall at least include the following tests: 8.1.3 _ Insulation tests: Insulation tests shall be in accordance with IEC 60146-1-1. Heat run The VFD shall run under the load and speed conditions at which the maximum temperatures will be reached, The unit shall run until the temperatures of all components have stabilized, and continue for at least a further 2h, It is not necessary to cover all operational conditions provided maximum power and minimum motor-cooling conditions have been tested. Measurements: Current Unbalance;BASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 30 OF 38 ‘+ Motor winding temperature rise (by resistance methods and by thermistors); = Converter temperature rises (temperature readings shall be complemented by an infra-red survey or equivalent identifying all potential hotspots including all power connection points. All suspect hotspots shall be checked against allowable component temperatures); ‘+ Bearing temperatures (at max. speed); ‘* Shaft vibration (if proximity probes are fitted). 8.1.4 Load tests: ‘© Overall efficiency measurement at full and half load curve both at minimum operational speed and at max. operational speed of the total unit and of the transformer, converter and motor individually; * Ditto for power factor; ‘+ Ditto for harmonic distortion in the current on the line side; ‘= Noise test (of all individual items); ‘* Output voltage characteristics: + Output current characteristics; = 110% full load current test for at least 10 min; * Linearity between set point signal and output. 8.1.5 Notload test (over the whole speed range) ‘+ Motor shaft voltage; + Motor noise test; ‘+ Vibration severity measured at bearing housing 8.1.6 Functional tests at 100 % supply voltage ‘+ Demonstrate rated torque capability (if this condition is not already covered under heat-run); = Test of speed protection: ‘+ at 102 % of the maximum operational speed (for power or torque controlled VFD); ‘+ at 105 % of the maximum operatonal speed at 95 % of the minimum operational speed; ‘+ Test of response times and adjustability (ramp times) within operational speed range; ‘+ Test capability to ride through voltage dips less than 20 %; + Test capability to restart VFD and resynchronize converter onto a running motor after a ‘+ Voltage interruption; ‘+ Test of 0-4-20 mA reference signal;BASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 31 OF 38 ‘+ Test of remote control conditions; ‘+ Test of output frequency/voltage reduction initiated by motor current limitation; + Test of 5 % ‘set point versus measured point’ deviation alarm; ‘+ Componentiauxiliary component failure; ‘+ Test of all protection, alarm and trip functions; = Auto start of standby auxiliaries. 8.1.7 Fault condition tests Type test results on units from the same design range can be accepted instead NOTE: For any of the tests mentioned below, the protection devices of the VFD may be activated. After resetting/ replacing these devices, the VFD shall be fit for operation again. © Two phase short circuit at motor terminals at no-load condition up to maximum rating of 1 MW; ‘+ Earth fault tests at the motor; ‘* One phase interruption of the motor cable at full-load condition (simulation above 1 MW); ‘+ One phase interruption in the VFD supply cable at full-load condition (simulation above 1 MW); ‘+ Three phase interruption of the metor cable at full-load condition (simulation above 1 mw); + Earth fault in the control supply system; ‘+ Interruption in the 4-20 mA control signal; ‘+ Short circuit in the 4-20 mA control signal. 8.1.8 Visual inspection Check drawings against the approved drawings and availability of instruction manuals. Verify degree of protection (IP) of cubicles. ‘Check simulation facility control signals for testing purposes. ‘Check memory function of fault diagnostic and indication logic. Verify availability of eye bolts for lifting heavy components. Verify that mains isolator is lockable in the off-position. Verify voltage/current rating power of semiconductor elements. Check terminal and wiring marking Check space available for cable termination, size and number of terminals, cable supporting devices. Check that wiring is not fixed directly to metal parts.BASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 32 OF 38 82 83 84 Check earthing of cubicles and cubicle doors containing electrical equipment. Verify marking of components according to the relevant drawings. Verify dimensions of converter. Verify accessibility of components and IP 2X protection. Check all external signals and indication/alarm signals on converter. Verify mass of converter. Check all rating plates of VFD main components according to specification. Routine Tests A routine test shall be carried out on every VFD not subjected to a performance test. Each routine test protocol shall refer to the original performance test protocol and the type and serial numbers of all components of that VFD. After the successful routine tests of the individual items (e.g. motor and transformer and reactors according to the respective specification) following testing shall be performed on the total VFD: « + No-load tests; ++ Insulation tests; ‘+ + Functional tests, excluding the locked rotor test and those tests requiring loads; ‘++ Visual inspection For an HV VFD the COMPANY may decide to limit the routine tests to the routine tests of the individual items only. The routine test of the complete string shall then be waived. If not specifically agreed with the COMPANY otherwise, the routine test of the complete string shall be included in the scope of supply. Special Tests \VFD for special duties or with special protection, etc. may require additional tests. These tests shall be described either in the requisition or the order or shall be required for the purposes of the certification of the type of protection. Integration test Integrated Test for VFDS package ie Combined FAT Performance Test of VFDS Package. This test shall be carried out by the VFD MANUFACTURER for Combined Performance Test of VFDS Package (Transformer +VFD+Motor) The following performance tests shall be conducted at manufacturer's place: 84.1 Heat Run 1. Temperature Rise Test ‘+ Stator winding temperature rise shall be < 66 K at ambient 54 ° CBASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 33 OF 38 ‘+ Bearing temperature rise K shall be < 36 * C and bearing temperature shall not exceed 90° C ‘+ VED temperature rise: use infrared survey or equivalent identifying all potential hotspots suspect hotspots shall be checked against allowable component temperatures. 84.2 Load Tests 2. Efficiency measurement and determination of the power factor at full load and half load and both at maximum and minimum operational speed. Overall efficiency of motor output/step-down transformer input Power factor in step-down transformer input Harmonic distortion in the current on the motor Output Voltage characteristics Output Current characteristics . Linearity between set-point signal and output No-Load Tests 7. Motor noise measurements at no-load according to ISO 1680 and ISO 3744 8. Frequency converter noise measurements — motor at no-load 9. Vibration measurement at no-load Vibration velocity measurements from bearing brackets (horizontal, vertical, axial). Maximum value 1.5 mm/s Vibration measurement of the shaft at no-load Vibration displacement measurements from the shaft ( and X) at no-load speed. Maximum value: shaft vibration (peak to peak) — 60 im 10. Shaft voltage at no-load Voltage measured between DE and NDE of shaft, if > 250 mV for rolling element bearing and > 400 mV for sleeve bearing, insulated sleeve bearing shall be provided (refer Motor DGS section 13.8.3) Functional Tests at 100% supply voltage 11. Locked rotor test: Testing of stall protection of the frequency converter — tripping after setting time fault condition tests 12. Earth fault test at the motor at no-load 13. One phase interruption of the motor cable at full-load condition © (simulation above 1MW)-N.A) 14. One phase interruption of the VED supply cable at fulload condition eae eeBASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 34 OF 38 ‘+ (simulation above 1MW) -N.A) 15. Three phase interruption of the motor cable at full-load condition-(simulation above aMW) 16. Interruption in the 4-20 mA control signal at no-load 17. Short-circuit in the 4-20 mA control signal at no-load Functional Tests at 100% supply voltage 18, Test of speed protection ‘= At 105% of maximum operational speed - should trip. (Over speed protection) ‘= At95% of minimum operational speed — should trip. (Under speed protection) 19. Test of the response times and adjustability (Ramp Times) within the operational speed range Demonstrate two different start ramps 20. Test capability to ride through voltage dips less than 20% 24 Test capability to restart VFNS and resynchronize converter onto a running motor after a voltage interruption. = atnoload + breaking timer of voltage = 4.5 sec (or test field limitation) 22. Test of 4-20 mA reference signal ‘+ Demonstrate linearity between reference value and motor speed 23. Test of remote control conditions * Tobe demonstrated via 4-20 mA signal from external and start/stop via terminals in the drive for DCS / motor control start/stop 24. Test of output frequency / voltage reduction initiated by motor current limitation: '* Motor current limitation of the converter shall reduce the output frequency /voltage. ‘Setting of motor current limiter and observation with drive windows. 25. Test of 5% - Set point / Measured point - deviation alarm 26. Component / auxiliary component failure ‘+ Open non-critical circuit breaker in the drive and see alarm message in the panel. 27. Auto start of standby auxiliaries ‘+ Open circuit breaker of the running pump, observe switch-over to redundant pump. 28. Test of all protection, alarm and trip functions 29. Demonstrate rated torque capabilityBASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 35 OF 38 9.0 10.0 DOCUMENTATION A fully detailed written bid is required together with all data requirements listed below: ‘+ Exceptions and deviations, if any; ‘+ Outline General Arrangement Drawings of the Equipment; ‘+ Completed Data Sheets; * Confirmation of scope of supply including detailed material and painting specifications; ‘+ Single line diagram, schematic diagram showing the main and auxiliary circuitry, including main switching devices, unit transformer, DC link, system earthing and auxiliary supplies; + Package dimensions; '* Foundation Loading Plan to indicate the critical loads at each support for all cases; ‘+ Schedule of Materials of Construction; ‘* Proposed manufacturing/ delivery schedule; ‘+ Proposed Quality Assurance/ Safety Plan; ‘+ Typical Inspection and Test Plan; ‘+ Test reports of type tests done on the system and the main components; * Certificates and ‘Declarations of Conformity’ for explosion protected equipment; + MANUFACTURER's proposed service and repair support after warranty. All documents shall show the relevant order number, item and MANUFACTURER's references, and shall be formatted and distributed as specified by the COMPANY. Documents shall be provided on a PC readable device (e.g. CD-ROM) unless otherwise specified by the COMPANY. PREPARATION FOR SHIPMENT The manufacturer shall take all measures to avoid any risk of damage or deterioration during shipping. When shipment is ty sea, equipment must be adequately protected against knock and salt water spray etc. In every case, consideration must be taken of the fact that equipment will remain at site exposed for long times in open air, damp, tropical, high sandstorm and dusty locetion. Wires for energizing space heaters during storage shall be brought out and tagged “Space Heaters” with the voltage and wattage shown. Transport units heavier than 25 kg shell have eye bolts, lugs or extension pieces clearly marked for hoistingBASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 36 OF 38 11.0 12.0 13.0 ‘SUPPLIER'S RESPONSIBILITY AND GUARANTEES ‘The manufacturer of the VFDS shall be responsible for the performance of the supplied \VFDS as specified in this specification and data sheet completed by the manufacturer. The manufacturer of the VFDS shall be responsible for compliance with the requirements of the motor and driven equipment The supplier is responsible for complying with all codes which apply to the equipment. Any special certification requirements or inspections by other authorities arising from the above shall be arranged by the supplier and the costs for the same shall be included in his quotation The equipment to be provided by supplier must be in complete compliance with this specification and reference codes. Any exception or deviations, if any must be listed separately with the quotation for Purchaser approval. Any exception which is not listed shall not be considered. ‘A complete set of tools for service and maintenance shall be supplied in a box suitable for wall mounting for each system. SITE INSTALLATION ASSISTANCE, COMMISSIONING AND START-UP Manufacturer shall provide a specialist for site installation supervision, assistance start up and commissioning supervision. Installation supervision shall include, but not limited, to the following: ‘+ Visual inspection. ‘© Check and supervision of mechanical installation. ‘= Check of alignment, assembly, inter wiring connections of the various unit shipped separately in order to assure that the equipment ready for connection of incoming and outgoing power cables and ready for operation. During the start up stage, manufacturer specialist shall carry out, but not limited, the following: ‘= Check of the correct execution of tne connections between assembled units. ‘+ Insulation test of all power, control, auxiliary circuits and equipment. © Dielectric withstand test of all power, control, auxiliary circuits and equipment. ‘+ Interchangeabilty of similar equipment. ‘© Check of functioning of the interlocks. ‘+ Test of functioning of all electrical circuits. ‘SPARE PARTS The following spare parts shall be included in suppliers’ quotation:BASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 37 OF 38 13.4 Commissioning spare parts ‘Commissioning spare parts shall be supplier responsibility but supplier shall submit a detailed list with his quotation. 13.2 Two year spare parts The supplier shall submit for each VFDS a detailed list of two years spare parts with his quotation. 14.0 HEALTH, SAFETY AND ENVIRONMENTAL MANAGEMENT ‘The supplier shall consider the impact on environment of his products during different process (e.g. designs, manufacturing etc), and shall develop environment friendly products and manufacturing processes such that the supplied equipment will be safe, efficient and in a ways that it conserve energy and other natural resources. The electrical equipment and products shall cover (in design, engineering, ‘manufacturing and testing processes) any emergency, abnormal and upset conditions Which would be met during equipment operation to prevent the following: ‘© Environmental damages. ‘+ Equipment or product damages. ‘+ Plant operation losses. + Health effects. © Loss of public & purchaser trust. 15.0 VENDOR DRAWING REVIEW Drawings retumed to VENDOR for correction after mark-up by EPC CONTRACTOR or his designated representative shall be resubmitted by VENDOR until “Proceed with Fabrication Issue Final Drawings’. All revisions to documents must be clouded and identified with the revision number contained within a triangle placed beside the cloud. The VENDOR shall not proceed with changes having a commercial impact unless authorized by Change Order. If, for any reason, VENDOR believes that he is not able to comply with the EPC CONTRACTOR's marked-up comments on the documents retumed after review, VENDOR shall notify, in writing, EPC CONTRACTOR immediately giving proper reasons justifications and requesting a resolution which will be reviewed by EPC CONTRACTOR. It is not acceptable to ignore marked-up comments without proper justification/reasons. Drawings and data approval does not relieve VENDOR of his responsibility to meet Purchase Order or Contract conditions relating to specifications, material design or construction, and delivery requirements, nor relieve VENDOR of responsibility for compliance with laws, codes and regulations,BASIC DESIGN DOC. NO.: GEN-ELE-SPC-0023 REV. B PAGE 38 OF 38 16.0 OPERATION CONSTRUCTION & MAINTENANCE MANUAL VENDOR shall provide Operating Instructions and Maintenance Manual. VENDOR shall also be responsible for providing manuals and other training aids such as videos for operator training,