Remotely Operable 1500V DC Disconnector & Short-Circuit Switch Assembly

Transcription

1 Specification Electrical Networks L1-CHE-SPE-128 Remotely Operable 1500V DC Disconnector & Short-Circuit Switch Assembly Version: 1 Issued: February 2016 Owner: Head of Engineering - Electrical Approved By: Andrew Russack Head of Engineering - Electrical PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION

2 Approval Amendment Record Approval Date Version Description 22/02/ Initial Issue PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 2 of 19

3 Table of Contents 1. Purpose Scope Acronyms and Abbreviations Definitions References & Legislation Standards Latest Issues and Amendments Operating Conditions Service Conditions Electrical Conditions Requirements Functional Requirements Ratings Non-Functional Requirements Operation Remote Operation Local Operation Manual Operation Control and Indication Requirements Construction Requirements Prohibited Materials Control Cabinet Mounting Connections Rating Plates Testing Type Testing Routine Testing Test Certificates Documentation and Support Drawing Requirements Technical Maintenance Plan Maintenance Manual Installation Instructions Training PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 3 of 19

4 11.6 Tools & Equipment Risk Management Product Development Appendix A - Design Management Requirements Appendix B Technical Data Schedule Form PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 4 of 19

5 1. Purpose This document is the MTM technical specification for a Remotely Operable 1500V DC Disconnector & Short-Circuit Switch Assembly, for use in the Melbourne Railway Traction System. 2. Scope This document applies to the supply of remotely operable 1500V DC Disconnector and Short-Circuit Switch Assemblies (Switch Assemblies) for use in the Melbourne Metropolitan Rail Network. Switch Assemblies will be installed as the point of isolation between DCCBs within substations or tie stations, and the traction overhead wiring, in place of a standard 1500V isolator or switch. 3. Acronyms and Abbreviations C&I Control & Indication DC Direct Current DCCB Direct Current Circuit Breaker EN Electrical Networks MTM Metro Trains Melbourne RTU Remote Terminal Unit SCADA Supervisory Control and Data Acquisition (System) 4. Definitions For technical terms, refer to EN Shall Should Switch Assembly Short- Circuiting Switch Is used as the descriptive word to express a requirement that is mandatory to achieve conformance. Is used as the descriptive word to express a requirement that is recommended in order to achieve compliance. Should can also be used if a requirement is a design goal but not a mandatory requirement. The entirety of the device specified in this document including the Disconnector, Short-Circuit Switch, electric drive unit(s), controls, interfaces and cabinets Mechanical switching device for short circuiting parts of the circuit, capable of withstanding for a specified time, currents under abnormal conditions, but not required to carry currents under normal conditions of the circuit. DC device analogous to an earthing switch PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 5 of 19

6 5. References & Legislation 5.1 Standards Document Number Title EN Railway Applications - Fixed installations D.C. switchgear General EN Railway Applications - Fixed installations D.C. switchgear - Outdoor d.c. disconnectors, switch-disconnectors and earthing switches AS Insulators - Porcelain and glass for overhead power lines - Voltages greater than 1000 V a.c. - Test methods - Insulator units AS AS Polymeric insulators for indoor and outdoor use with a nominal voltage > 1000 V General Definitions, test methods and acceptance criteria High-voltage switchgear and controlgear - Common specifications PTV Infrastructure Drafting Standards The Switch Assembly shall primarily comply with the requirements of EN :2003 Railway Applications - Fixed installations D.C. switchgear - Outdoor D.C. disconnectors, switch-disconnectors and earthing switches All materials and components shall comply with the relevant Australian Standard or, where these do not exist, shall comply with the relevant IEC or EN Standard. 5.2 Latest Issues and Amendments Reference to all standards shall be read as a reference to the latest edition of that standard and amendments available at the time of tendering. 6. Operating Conditions 6.1 Service Conditions The Switch Assembly will be installed outdoors, either on the wall of a traction substation or tie station, or on a mast with other components of the traction overhead wiring system The normal outdoor service conditions as stated in AS shall apply except that the maximum ambient air temperature shall be taken to be 45 C. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 6 of 19

7 6.2 Electrical Conditions The Switch Assembly will be used in the supply of 1500V DC traction power to trains in the Melbourne Railway Traction Power Supply Network. This Network consists of traction substations, tie-stations, and an overhead wiring system If installed on a substation or tie station wall, the frame of the switch assembly will be connected directly to the substation negative busbar If mounted on a mast, the frame should be connected to the rail via the mast and its spark gap, with 3kV insulation between the frame and the short circuit terminal of the switch. Alternatively, it may be insulated to 3kV DC from the mast and connected directly to rail The voltage of the 1500V DC network at the substations and tie-stations typically varies between 1000V DC and 1850V DC The overhead contact wire network typically consists of sections between 3 and 5 kilometres in length. It is susceptible to lightning and short-circuits, typical of this type of construction and use The maximum prospective fault current of the 1500V DC network at the substations is typically in the range of 30,000A to 120,000A. The time constant of the fault current is generally in the range of 5 to 20 milliseconds. 7. Requirements 7.1 Functional Requirements The Switch Assembly shall have three states: Connected, Disconnected and Short- Circuited. (a) The Connected state shall provide a connection between the DCCB and the overhead wiring. (b) The Disconnected state shall provide an appropriate isolating distance between the DCCB connection and the overhead wiring. (c) The Short-Circuited state shall connect the overhead to either the negative busbar, for switches located on substation walls; or to the negative rail for switches located on masts. (Refer to section 6.2) The Switch Assembly may be composed of one, three position device, or a separate but mechanically interlocked disconnector and short circuiting switch The Switch Assembly shall be able to be operated between the Connected and Disconnected states, and between the Disconnected and Short-Circuited states, but not directly between the Connected and Short-Circuited states The Switch Assembly shall be able to be power operated remotely (via SCADA), power operated locally, and manually operated. Operation shall be dependent power operation and dependent manual operation. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 7 of 19

8 7.1.5 The state of the Switch Assembly shall be clearly and unambiguously identifiable by visual inspection from ground level at a distance within 3m of the supporting mast or wall The Switch Assembly shall not be able to be power operated to the Short-Circuited state unless the line side voltage is less than 400V. A voltage transducer shall be provided within the Assembly for this purpose The Switch Assembly shall have confirmation of continuity to the negative busbar/rail, prior to operating electrically from the Disconnected state to the Short- Circuit state The Control Voltage of the Switch Assembly shall be 48 V DC, 110 V DC or 125V DC, or 230V single phase 50Hz AC. The Switch Assembly shall be capable of operating from any of these voltages without the replacement of parts Failure of the control circuitry shall result in no change in state of the Switch Assembly. If a loss of control voltage occurs, on restoration the Switch Assembly will remain in its current position A local counter shall record the number of electrical operations of the Switch Assembly, between the Connected and Disconnected states, and separately between the Disconnected and Short-Circuit states. 7.2 Ratings The Disconnector and Short-Circuit Switch functions shall both meet or exceed the following ratings in accordance with EN : Nominal Voltage: 1,500 Volts DC Highest Normal System Voltage: 1,850 Volts DC Lowest Normal System Voltage 1,000 Volts DC Insulation Voltage: 3,000 Volts DC Impulse Withstand Voltage: 95,000 Volts (Peak) Power Frequency Withstand Voltage (wet): 50,000 Volts AC (50 Hz) Service Current (Disconnector only): 4,000 Amps DC Rated Making Current: 0 Amps DC Rated Breaking Current: 0 Amps DC Rated Short-Time Withstand Current (t = 250ms): 20,000 Amps DC Number of poles 1 Rated Mechanical Endurance, without replacement of parts: 10,000 Cycles PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 8 of 19

9 7.3 Non-Functional Requirements The Assembly shall be designed and manufactured to give the highest level of inservice reliability, whilst requiring a minimum level of maintenance under continuous operating conditions The switch assembly shall be configured in a manner that allows it to be easily maintainable and replaceable, either in whole or in part in the event that it becomes faulty The Switch Assembly should have a minimum life, considered as the time to replacement of major components, of 25 years The Switch Assembly should have a recommended maintenance regime requiring attendance not more than once every 3 years. Routine maintenance and inspections should be able to be conducted from the ground using appropriate tools. 8. Operation 8.1 Remote Operation Remote Operation of the Switch Assembly shall be facilitated by an interface with the SCADA system as described in section A delatching operation shall be required in order to operate the Switch Assembly from the Short-Circuited state to the Disconnected state via SCADA 8.2 Local Operation Local Operation shall be facilitated through provision of a control panel mounted within a padlocked cabinet as described in section 9.1 to protect against unauthorised operation and vandalism A local control shall be provided to operate the Switch Assembly between the Connected and Disconnected states, and a separate control provided to operate the Switch Assembly between the Disconnected and Short-Circuited states, subject to clause Alternatively four separate controls may be provided, one for each possible transition A local control shall be provided to disable remote operation of the Switch Assembly. This control shall be designated Remote Control Isolating Switch. This switch shall interrupt all the control connections described in section 8.4 whilst maintaining the indications described in that section The local control panel shall feature indicating lamps of the long life LED type, indicating as a minimum: (a) for each of the three states, if the Switch Assembly has been positively detected in that state, (b) if remote operation has been disabled, PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 9 of 19

10 8.3 Manual Operation (c) if negative continuity to rail is detected, and (d) whether or not the line voltage is below the threshold described in clause The state of the indicator lamps shall be readable in daylight conditions. A lamp test function shall be provided to test the lamps are in working order Manual Operation shall be provided so that the Switch Assembly may be operated when the control voltage is not available Manual Operation shall enable operation of the switch to each of the three states by one person from ground level Any special tools required for manual operation of the Switch Assembly should be provided and stored within the Control Cabinet The Switch Assembly shall be protected from unauthorised manual operation by inclusion of a padlocking facility. For operating handles, the handle must be able to be padlocked in position in the Connected, Disconnected, or Short-Circuit state. For cranking arrangements, the socket for any crank handles shall not be accessible without removal of a padlocked shutter. 8.4 Control and Indication Requirements Remote operation of the Switch Assembly shall be controlled through a hardwired interface with an RTU The interface between the control cabinet and the SCADA control circuits shall use interposing relays. The current consumption of the interposing relay coil shall be 60 to 100 ma at the control voltage. The SCADA RTU provides a 1 second duration pulse to the interposing relay Five Interposing Relays shall be provided for control: (a) One Interposing Relay shall cause the Switch Assembly to operate from the Disconnected state to the Connected state. If the Switch Assembly is not in the Disconnected state, it shall have no effect. (b) One Interposing Relay shall cause the Switch Assembly to operate from the Connected state to the Disconnected state. If the Switch Assembly is not in the Connected state, it shall have no effect. (c) One Interposing Relay shall cause the Switch Assembly to operate from the Disconnected state to the Short-Circuited state. If the Switch Assembly is not in the Disconnected state, or if the line-side voltage is not measured to be less than 400V (refer 7.1.6), or if continuity of the negative connection has not been detected (refer 7.1.7), it shall have no effect. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 10 of 19

11 (d) Two Interposing Relays shall be provided to operate the Switch Assembly from the Short-Circuited state to the Disconnected state. One relay is to be provided as a delatching relay to prevent the accidental operation of the Switch Assembly to an unsafe state in the event of a single point failure of the control system. If the Switch Assembly is not in the Short-Circuited state they shall have no effect Two normally open and two normally closed voltage free contacts shall be provided for each of the following indications: (a) the Switch Assembly has been positively detected in the Connected state, (b) the Switch Assembly has been positively detected in the Disconnected state, (c) the Switch Assembly has been positively detected in the Short-Circuited state, (d) the Switch Assembly is in transition between the Connected and Disconnected states, and (e) the Switch Assembly is in transition between the Disconnected and Short- Circuited states Analog indications of the detected line voltage shall be provided by 4-20mA terminals A voltage free contact shall be provided to indicate the state of the control cabinet door, which may be either open or closed A set of changeover contacts shall be provided to indicate failure of each electric drive unit A set of changeover contacts shall be provided to indicate continuity to the negative busbar or rail, which may be either open or closed Any electronic control devices shall provide a watchdog type health indication contact for connection to the SCADA system Relays and contacts should be suitable for connection to control voltages of 48VDC, 110VDC and 125VDC All the Control and Indication points shall be provided on a single terminal strip and shall be suitable for connection to cabling in accordance with MESP Technical Specification for SCADA Cabling in Substations A minimum of 3000V DC electrical isolation shall be provided between each of the C&I terminals and the 1500V DC connections, traction negative connections, control voltage connections, mast and cabinets. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 11 of 19

12 9. Construction Requirements 9.1 Prohibited Materials There shall be no asbestos or materials containing asbestos in the Switch Assembly or its packing. A statement certifying that the product is free of asbestos containing materials must be completed and signed, and delivered to MTM prior to despatch. 9.2 Control Cabinet One or more cabinets shall be supplied, and between them shall contain: (a) the local control panel including indicating lamps; (b) space and fittings for the storage of any special tools required; (c) terminal strips for SCADA connection as described in section 8.4, which shall be provided within the primary cabinet; (d) LV power terminals, which shall be provided within the primary cabinet; and (e) electric drive unit(s) for the Switch Assembly The cabinet(s) shall be constructed of grade 316 stainless steel, with a minimum thickness of 1.6mm The cabinet(s) shall be tamper-proof, and all doors shall be padlockable or be secured with security screws The cabinet(s) shall be rated to a minimum of IP The cabinet(s) shall be designed to prevent the ingress of water into the cabinet while open, such as in wet weather conditions The cabinet(s) shall be mounted on the mast or wall as described in section Where provision is made for padlocks, the holes for the padlocks shall be 10 mm in diameter 9.3 Mounting The Switch Assembly shall be suitable for mounting both on masts and on substation or tie station walls. Mountings should as far as possible utilise existing standard parts such as those shown in drawings D4192, D4195, D4263, D7814, D7920, F11071 and Q6346 and be suitable for mounting using existing anchor points The Switch Assembly may be mounted as up to four individual components switch(es), operating mechanism, control cabinet and operating rod The maximum weight of each individual component shall not exceed 55kg. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 12 of 19

13 9.3.4 Two Switch Assemblies shall be able to be mounted on a opposite sides of a 250 UC or 310UC mast, and one Switch Assembly should be able to be mounted on such a mast alone, or with an existing 1500V DC switch Switch Assemblies shall be designed and sized appropriately in order to be able to be mounted on substation walls with a minimum horizontal separation of 500mm between centre lines The minimum height above ground level of exposed uninsulated components shall be 5500mm Installation of the Switch Assembly shall not render masts or walls readily climbable. 9.4 Connections The primary connections shall be presented on copper palms suitable for the connection of up to three single core 500mm 2 Aluminium cables, terminated with suitable lugs The connection(s) to rail or the negative bus shall be presented on copper palms suitable for connection of two 70-90mm 2 copper or 300mm 2 aluminium cables, terminated with suitable lugs. 9.5 Rating Plates Two rating plates shall be affixed to the Switching Assembly, one as close as possible to the actual switching device(s), and one to the control cabinet The rating plate adjacent to the switching device(s) shall include the following information: (a) name of the manufacturer or trademark; (b) reference to EN and any other standard to which the switch complies; (c) class and category (of each switching device if applicable); (d) serial number designation; (e) year/month (mm/yy) of manufacture; (f) rated voltage(s) U Ne ; (g) rated service/thermal current, I Ne, I th or I the ; (h) rated breaking current, if applicable; (i) rated making current, if applicable; (j) rated short-time withstand current I Ncw ; (k) input and output terminals, unless they can be connected either way; (l) earth terminal, if applicable, by the symbol; PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 13 of 19

14 9.5.3 The rating plate affixed to the control cabinet shall include the following information: (a) name of the manufacturer or trademark; (b) reference to EN and any other standard to which the switch complies; (c) serial number designation; (d) year of manufacture; (e) weight of the complete unit and of each separately removable part; (f) auxiliary and control supply voltages; (g) earth terminal, if applicable, by the symbol; The rating plates shall be constructed of stainless steel and shall be securely riveted to the Switch Assembly Recorded information shall be physically etched, embossed or engraved clearly onto the surface of the rating plates and shall be highlighted with black paint. 10. Testing 10.1 Type Testing The type tests prescribed in EN shall be successfully performed at the manufacturer s factory for every variation of design MTM reserves the right to appoint a representative to witness these tests. Seven working days notification shall be given to MTM of intention to carry out factory testing Routine Testing The routine tests as described in section 8 of EN : 2003 shall be performed on the Switch Assembly at the manufacturer s factory MTM reserves the right to appoint a representative to witness these tests. Seven working days notification shall be given to MTM of intention to carry out factory testing Test Certificates The results of all tests shall be recorded on test certificates. The test certificates shall clearly show the performance of the equipment and shall be accompanied by tables showing the actually measured values and all calculations The test certificates shall be forwarded to MTM and the results approved by MTM prior to delivery. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 14 of 19

15 11. Documentation and Support 11.1 Drawing Requirements All equipment drawings shall comply with the PTV Infrastructure Drafting Standard and shall be submitted for MTM approval prior to manufacturing Drawings shall be provided on Compact Disc in both PDF and Microstation formats Technical Maintenance Plan A Technical Maintenance Plan which establishes the recommended maintenance policy for the Switch Assembly shall be provided The Technical Maintenance Plan shall detail the preventative servicing schedules and maintenance intervals for the Assembly. The servicing schedules shall reference appropriate detailed instructions in the maintenance manual The Technical Maintenance Plan shall detail safe disposal procedures applicable for when the Switch Assembly is no longer serviceable (recycling, hazardous waste etc.) Maintenance Manual The Maintenance Manual shall detail: (a) The theory of operation of the Switch Assembly. (b) All servicing activities. (c) Overhaul instructions. (d) Adjustment procedures. (e) The changing of components for repairs. (f) Fault-finding procedures. (g) The spares support schedule detailing price, supplier and procurement leadtimes The Maintenance Manual shall include a complete set of as-built drawings (complying with section 11.1) and a comprehensive parts list for the Assembly Installation Instructions The installation instructions shall enable the Switch Assembly to be properly installed, tested and commissioned. This shall include all necessary drawings. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 15 of 19

16 11.5 Training Any required training for remote, local, and manual operation shall be provided to MTM staff Documentation on the operation of the equipment through various operating methods shall be clear and concise, and freely available to operators 11.6 Tools & Equipment A complete set of operating tools and any other equipment necessary to operate and maintain the Switch Assembly shall be provided. This shall include any special device required to test the Switch Assembly. Storage facilities for the tools and equipment shall also be provided Risk Management The supplier shall provide any reasonable information on the proposed product requested by MTM, for the purposes of conducting Risk Assessments, which may include, but is not limited to: drawings, logic designs, reliability ratings, and maintenance regimes A representative of the supplier may be requested to participate in the risk assessment workshop, in order to provide specific information on the development of the product Product Development The supplier shall work collaboratively and iteratively with MTM to ensure the most appropriate product is delivered. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 16 of 19

17 12. Appendix A - Design Management Requirements This appendix describes the documentation which should be provided as a minimum at each stage of the procurement process. The documentation shall comply with the specifications above. Tender Submission The following documents shall be provided as part of the tender submission: General Arrangement drawing of the Remotely Operated 1500V DC Disconnector & Short-Circuit Switch Assembly which clearly shows: o The overall dimensions of the Assembly o Details of the proposed cable terminals and cable entry requirements Pamphlets and technical details of the operation of the assembly and its components Type Test Certificates The Technical Data Schedule in Appendix B filled in A list and pricing for recommended spare parts Any other information considered necessary to gain a full understanding of the offer Contract Documentation One set of PDF copies of the drawings and documentation, as described in Section 11, should be provided for review and approval by MTM four weeks after the Contract Award Date. No manufacture shall commence until the drawings have been approved. An allowance of ten working days should be made by the supplier for the review and approval of submitted drawings. Pre-Delivery Documentation At the time of delivery, the supplier shall provide five hard copies of the following documents: Technical Maintenance Plan Maintenance Manual Installation Instruction Manual Operation Instruction Manual Storage, handling, loading, and off-loading instructions Test Certificates Approved Drawings In addition to the hard copies, the supplier shall, after final acceptance of the Assembly, provide copies of the As Built layouts and Schematic drawings in electronic format (PDF and Microstation) PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 17 of 19

18 13. Appendix B Technical Data Schedule Form The Tenderer shall supply the following information and guarantee performance thereof. Compliance a. Does the Assembly fully comply with this Specification? YES / NO b. Are Type Test Certificates attached? YES / NO c. Are General Arrangement drawings attached? YES / NO d. Have relevant pamphlets and technical information been attached? YES / NO e. Is a list of recommended spare parts attached? YES / NO Electrical a. Rated Operating Voltage V DC b. Rated Insulation Voltage V DC c. Rated Impulse Withstand Voltage kv Peak d. Rated Power Frequency Withstand Voltage (1 min, wet) kv RMS e. Rated Continuous Current (Disconnector) A DC f. Rated Short Time Withstand Current ka DC g. Rated Short Time Withstand Duration ms h. Class of Use... i. Rated Making Current A j. Rated Breaking Current A k. Control Voltages V DC/AC l. Current consumption at Control Voltage for Operation A m. Main / Short Circuiting Contact Material... n. Resistance of Main Circuit Ω o. Resistance of Short-Circuiting Circuit Ω PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 18 of 19

19 General a. Power operation mechanism... b. Manual operation mechanism... c. Isolating Distance mm d. Minimum distance between the Switch Assembly and earthed metalwork mm e. Rated mechanical endurance cycles f. Design life years Construction a. Weight of each component (refer 9.3.2) kg b. Maximum Dimensions of Switch Assembly c. IP Rating of cabinet(s) d. Number of padlocks required PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 19 of 19