Engineering Specification Electrical Networks TECHNICAL SPECIFICATION FOR A RECTIFIER UNIT CONTROL & PROTECTION SYSTEM FOR USE IN THE 1500V Version: 1 Issued: March 2014 Owner: Electrical Networks Asset Manager Approved By: George Marulli Electrical Networks Asset Manager PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION
Approval Amendment Record Approval Date Version Description 18/03/2014 1 Initial issue under MTM. Supercedes MainCo document MESP 0001. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 2 of 15
Table of Contents 1. Purpose... 5 2. Scope... 5 3. Abbreviations... 5 4. Definitions... 5 5. References & Legislation... 5 5.1 Standards... 5 5.2 Latest Issues and Amendments... 5 6. Background... 6 7. Housing... 6 8. Control Supply... 7 9. SCADA Voltage... 7 10. Control Interfaces... 7 10.1 General... 7 10.2 Rectifier ACCB Interface... 7 10.3 Rectifier DCCB Interface... 8 10.4 Rectifier DC Isolator Interface (where there is no Rectifier DCCB)... 8 10.5 Local Control Panel... 8 10.6 SCADA Interface... 9 11. Protection Functions... 9 11.1 General... 9 11.2 AC Overcurrent and Earth Fault System... 9 11.3 Rectifier Assembly DC Frame Earth Leakage... 10 11.4 AC Undervoltage, Phase Failure, Phase Loss and Phase Reversal... 10 11.5 Lockout Functions... 10 12. Monitoring Functions... 11 13. Cubicle Requirements... 11 13.1 Labelling... 11 13.2 Terminal Strips and Wiring... 11 14. Testing... 12 14.1 Factory Tests... 12 14.2 Test Certificates... 12 15. Documentation and Support... 12 15.1 Documentation Requirements... 12 PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 3 of 15
15.2 Design Drawings... 12 15.3 Drawing Format... 13 15.4 Installation Manual... 13 16. Appendix A Design Management Requirements... 14 17. Appendix B Technical Data Schedule Form... 15 PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 4 of 15
1. Purpose This document is the technical specification for a Control & Protection System for an MTM Rectifier Unit. 2. Scope This specification shall be applied in full for all new Rectifier Unit Control & Protection Systems to be installed in MTM Substations. 3. Abbreviations ACCB - Alternating Current Circuit Breaker DCCB - Direct Current Circuit Breaker Electrol - Electrical Systems Control Centre MTM - Metro Trains Melbourne SCADA - Supervisory Control and Data Acquisition RTU - Remote Terminal Unit (of the SCADA system) 4. Definitions Lock Out Shall Should The ACCB or DCCB is tripped by the operation of one or more protective devices and cannot be reclosed until an operator has attended on site to reset the lockout Is used as the descriptive word to express a requirement that is mandatory to achieve conformance to the standard. Is used as the descriptive word to express a requirement that is recommended in order to achieve compliance to the standard. should can also be used if a requirement is a design goal but not a mandatory requirement. 5. References & Legislation 5.1 Standards The Rectifier Unit Control & Protection System shall comply with Australian Standards including: AS 2067 AS/NZS 3000 Substations and high voltage installations exceeding 1 kv a.c. Wiring Rules 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. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 5 of 15
6. Background The Rectifier Unit Control & Protection System covered by this document will be used in MTM Traction Substations. These Substations primarily convert electricity from high voltage AC to 1500V DC power for the MTM Electric Train System. The Rectifier Assembly is one part of the Substation Rectifier Unit which consists of the Rectifier ACCB, Rectifier Transformer, Rectifier Assembly, Rectifier Unit Control & Protection System and Rectifier DCCB or Isolator as illustrated below. Rectifier Unit Rectifier ACCB Rectifier Transformer Rectifier Assembly Rectifier DCCB or Isolator Control & Protection System for 1500V DC Rectifier Unit Local Control Panel RTU Substation Battery (Control Supply) SCADA System Electrical Systems Control Centre The function of the Control & Protection System is to provide the control, protection and monitoring of the whole Rectifier Unit and all of its components. The Control & Protection System consists of all the components and systems required for this including switches, protection relays, control relays, indicating lights, cables, test blocks, terminal strips, transducers etc. The Control & Protection System is the main interface between the Rectifier Unit and the Substation RTU which then allows remote monitoring by the Electrical Systems Control Centre via the SCADA system. 7. Housing 7.1 The Control & Protection System components shall be mounted in a dedicated control cubicle. 7.2 The Cubicle should be located adjacent to the Rectifier Assembly. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 6 of 15
8. Control Supply 8.1 The Control Supply will be from the Substation Control Battery. It may be 50V, 110V or 125V DC depending on the location and will be specified separately in a scope of works document. 8.2 The negative of the Control Supply may or may not be connected to the substation earth at the Substation Control Battery. 8.3 All Control Relays shall have one side of their coils connected to the Control Supply Negative and shall be energised by the switching of the Control Supply Positive, either by switches or other relay contacts. 9. SCADA Voltage 9.1 The substation SCADA operating voltage may be 48V, 110V or 125V DC depending on the location. 9.2 It is important to note that the SCADA operating voltage may be different to the Control Supply voltage. 9.3 All SCADA Interposing Relays shall have coils rated to operate at the SCADA operating voltage. 10. Control Interfaces 10.1 General 10.1.1 The precise details of the control functions required will depend on the particular installation, however general requirements are described in the following sections. 10.2 Rectifier ACCB Interface 10.2.1 The Rectifier ACCB is the primary Rectifier Unit control and protection device 10.2.2 The Rectifier Unit shall be switched on and off by the Rectifier ACCB. 10.2.3 The protection tripping of the Rectifier Unit shall be performed by the Rectifier ACCB, except in the case of DC faults. 10.2.4 The control of the closing of the Rectifier ACCB shall be inhibited by: The AC Under Voltage device Loss of the Control Supply The protection Lockout device Any other thing considered appropriate 10.2.5 The Control & Protection System shall provide a selectable output interface to the ACCB which is capable of operating both conventional coil-operated (by means of a Control & Protection System voltage pulse) and PLC switched (by means of voltagefree contacts) ACCBs. 10.2.6 The Control & Protection System shall include a single-shot closing circuit which prevents instant re-closure of the ACCB in the event that it fails to remain closed after the initial attempt. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 7 of 15
10.3 Rectifier DCCB Interface 10.3.1 Under normal operating conditions, the Rectifier DCCB acts as a slave of the Rectifier ACCB. If present, the Rectifier DCCB shall be closed by the successful closing of the Rectifier ACCB and opened by the opening of the Rectifier ACCB. 10.3.2 The normal operation, as described in 10.3.1 shall be controlled via a single auxiliary contact of the Rectifier ACCB. Reserved terminals shall be included on the Control & Protection System terminal strip for the marshalling of this contact. 10.3.3 If the Rectifier DCCB trips automatically, the Rectifier ACCB shall be tripped and the Rectifier Unit shall be locked-out. 10.3.4 An auxiliary contact of the Rectifier DCCB shall be used to perform the function described in 10.3.3. An indication of this event shall be provided on the Local Control Panel and to the SCADA system via a set of changeover contacts. 10.4 Rectifier DC Isolator Interface (where there is no Rectifier DCCB) 10.4.1 The Rectifier DC Isolator shall be normally closed. 10.4.2 A mechanical or key interlock system shall be provided to prevent the Isolator from being opened or closed if the Rectifier ACCB is closed. 10.5 Local Control Panel 10.5.1 A Local Control Panel shall be provided for the Rectifier Unit and located on the Control & Protection System Cubicle. 10.5.2 The Local Control Panel shall have the following components mounted on the front of it: Control Switch Rectifier ACCB status indicating lights Rectifier DCCB status indicating lights Protection Trip indicating lights (both AC and DC) SCADA Isolating Control Switch Any permanent monitoring indications not directly connected to the SCADA system. 10.5.3 Indicating lights shall be long life, high reliability light emitting diodes (LEDs). If lights are used for fault indications they shall be permanently on until they are manually reset, even if there has been a Control Supply power failure. 10.5.4 A means shall be provided for the resetting of any trip indication lights and for the testing of all indication lights. 10.5.5 The Control Switch shall be used to locally switch the Rectifier Unit on and off. It shall be a rotary, spring return to neutral switch with a pistol grip handle. 10.5.6 The SCADA Isolating Control Switch shall disable remote operation of the Rectifier Unit. It shall not isolate any remote indications. The switch shall be a rotary switch, shall have a yellow escutcheon plate, and shall be labelled C&I Isolating Switch. 10.5.7 The Panel shall be labelled Rectifier Unit Control. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 8 of 15
10.6 SCADA Interface 10.6.1 The Control & Protection System shall interface with the SCADA system via the substation RTU. 10.6.2 All points that are to be controlled or indicated to the SCADA system shall be connected by a 3-wire system in accordance with MESP 081000-01 Technical Specification for SCADA cabling in Substations 10.6.3 Each point to be controlled shall be operated via interposing relays. The relay coils of each controlled point shall be connected to an independent common. 10.6.4 Each point that is indicated shall be indicated by a set of changeover contacts. Each point shall have its own independent common connection 10.6.5 Each point that is both controlled and indicated shall be brought to sequential terminals on the terminal strip. 10.6.6 SCADA control of the Rectifier ACCB shall be provided via: Operate Close Interposing Relay Operate Open Interposing Relay The interposing relay coil shall have a minimum resistance of 2000 Ω and be rated to operate at the SCADA operating voltage. The operate pulse time of the SCADA system is 1 second. 10.6.7 Both Open and Closed Indications of the Rectifier ACCB and DCCB or DC Isolator shall be provided to the SCADA system. These indications shall be via direct auxiliary contacts of the equipment. The terminal strip shall have an allowance for this. 11. Protection Functions 11.1 General 11.1.1 The Control & Protection System shall provide all the protection functions necessary for the safe operation and protection of the Rectifier Unit and its components. 11.1.2 The following protection functions are mandatory as a minimum: AC Overcurrent AC Earth Fault Rectifier Assembly DC Frame Earth Leakage Rectifier Unit Input AC Undervoltage and Phase Failure 11.2 AC Overcurrent and Earth Fault System 11.2.1 The AC Overcurrent and Earth Fault system shall include Test Disconnect Terminals for secondary injection testing. The preferred type of test link block is a Weidmuller type WTL 6/1 however other types may be used if approved by MTM during the design phase. 11.2.2 The preferred Rectifier Unit AC Protection Relay is an AREVA MiCom P123 series relay. Any alternative relay proposed must be approved by MTM during the design phase and shall: PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 9 of 15
Contain a selectable inverse time curve identical to the specification for the Rectifier curve of the MiCom P123 series relay Be programmable to allow multi-stage trip settings Have latching LEDs or mechanical flags that are capable of being programmed to indicate each tripping function of the relay Be microprocessor based and capable of storing the details of the 5 most recent trips, complete with date and time stamps. A Watchdog Timer function 11.2.3 The Watchdog Timer function of the Rectifier Unit AC Protection Relay shall be connected to the SCADA terminal strip for direct connection to the SCADA system. The failure of the Watchdog Timer function shall not cause a protection trip. 11.3 Rectifier Assembly DC Frame Earth Leakage 11.3.1 The Rectifier Assembly contains a DC Frame Earth Leakage Relay that is connected between the Rectifier Assembly enclosure and the substation earth. 11.3.2 Upon operation of the Rectifier Assembly DC Frame Earth Leakage Relay, the Control & Protection System shall trip the Rectifier ACCB. 11.3.3 If the Rectifier Unit does not include a Rectifier DCCB, the Control & Protection System shall trip the Section DCCBs in the substation via device 94B, Section DCCB Tripping Relay. This device is located on the Control Supply Switchboard. 11.3.4 Provision shall be made to allow an auxiliary contact of the Rectifier Assembly DC Frame Earth Leakage relay to be wired to the main terminal strip through a set of Test Disconnect Terminals for connection to the RTU. 11.4 AC Undervoltage, Phase Failure, Phase Loss and Phase Reversal 11.41 The AC Undervoltage (3 phase), Phase Failure, Phase Loss and Phase Reversal protection shall include a definite time delay for all functions that is adjustable between 1 and 10 seconds. This would nominally be set at 5 seconds and shall not be affected by any disturbance of the AC supply. 11.5 Lockout Functions 11.5.1 The occurrence of a lockout event shall prevent the Rectifier ACCB and Rectifier DCCB (or Section DCCBs where a Rectifier DC Isolator is fitted) from being re-closed until the Rectifier Unit has been inspected, the fault isolated and the lockout device manually reset via the Local Control Panel. 11.5.2 The following protection functions shall be considered lockout events: Rectifier Assembly DC Frame Earth Leakage AC Earth Fault Contacts from critical Rectifier Transformer temperature detection Contacts from critical Rectifier Assembly over-temperature detection Any other critical fault that requires an inspection before re-closure PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 10 of 15
12. Monitoring Functions 12.1 All monitoring functions shall interface with the SCADA system. 12.2 The Control Supply voltage shall be monitored and an indication of the loss of supply shall be given to the SCADA interface. The device monitoring the supply shall have a normally open and a normally closed changeover output contact. 12.3 The monitoring functions shall include warnings that the Rectifier Unit is approaching the rated voltage and current values. 12.4 All warning indications should have normally open and normally closed changeover output contacts. 13. Cubicle Requirements 13.1 Labelling 13.1.1 All devices, enclosures and circuits shall be clearly and permanently labelled for easy identification. The device numbers, etc. will be determined by MTM, and advice given before manufacture. Refer to MESP 000003-06 - Substation Device Naming, Numbering and Labelling. 13.1.2 All labels shall be of the Traffolyte type with engraved black lettering on white background. 13.1.3 A label "Rectifier Unit Control" shall be provided toward the top of the cubicle on the front. 13.1.4 All components mounted on the front shall be labelled by name and device numbers where applicable. 13.1.5 All components mounted inside the cubicle shall be labelled by their device number or fuse number, where applicable. Components visible on both the outside and inside of the cubicle shall be labelled inside and outside. 13.1.6 All wiring shall be clearly and permanently marked for easy identification. Each wire shall be uniquely identified and marked in the same way at both ends of the cable, with the same marking identified on the relevant drawings. 13.2 Terminal Strips and Wiring 13.2.1 A separate terminal strip shall be provided inside the cubicle for the connection of all external cabling. 13.2.2 Terminals shall be grouped together in functional groups and shall be segregated by voltage. 13.2.3 At least 50 spare terminals shall be available for the marshalling of other control and protection devices. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 11 of 15
14. Testing Tests shall be performed on the Control & Protection System as described below 14.1 Factory Tests 14.1.1 The manufacturer shall design a comprehensive test plan to be undertaken as factory testing which will be approved by MTM prior to manufacture. 14.1.2 All parts of the Control & Protection System able to be factory tested shall be factory tested for insulation functionality and operation. 14.1.3 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. 14.2 Test Certificates 14.2.1 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. 14.2.2 The test certificates shall be forwarded to MTM and the results approved by MTM prior to delivery. 15. Documentation and Support 15.1 Documentation Requirements 15.1.1 All documentation shall be provided in English. 15.1.2 One electronic and eight paper copies of the each document shall be provided and the content shall be identical in each copy. 15.1.3 Every page of the documentation shall be clearly identified in relation to the document to which it belongs and the version of that document. All pages of multipage documents shall be uniquely numbered. It shall be possible to readily determine if all pages of a document are present. 15.1.4 Manuals shall be A4 size and shall be bound in durable covers or in 4-D ring binders. 15.2 Design Drawings The following drawings must be supplied: i. A single Control & Protection Circuit Diagram ii. iii. iv. Construction details of the Rectifier Unit Control & Protection System Cubicle including dimensions. Physical layout and arrangement of the components in the Cubicle and on the Local Control Panel Mounting requirements for the Cubicle. v. Physical layout and arrangement of the cable connections and terminal blocks in the Cubicle. vi. All other drawings required for Installation, Testing, Commissioning, Operation and Maintenance including a complete parts list. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 12 of 15
15.3 Drawing Format 15.3.1 All drawings must comply with VRIOGS 007.2 - Infrastructure Drafting Standard and shall be submitted for MTM approval prior to manufacturing. 15.3.2 Files shall be provided in Microstation format on compact disk (CD). 15.4 Installation Manual 15.4.1 An Installation Manual shall be provided and shall include instructions which enable the 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 13 of 15
16. 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 are to be provided as part of the tender submission: General Arrangement drawing of the Rectifier Unit Control & Protection System Cubicle Proposed factory testing procedure The Technical Data Schedule in Appendix B filled in. Contract Documentation One set of PDF copies of the documentation described in section 15.2 should be provided for review and approval by MTM four weeks after the Contact Award Date. No manufacture shall commence until the drawings have been approved. An allowance of five working days should be made by the supplier for the review and approval of submitted drawings. Any required alterations will require resubmission and another review of the drawings. Pre-Delivery Documentation The supplier shall provide five hard copies of the following documents at the time of delivery: Installation Manual Test results Approved drawings In addition to the hard copies, the supplier shall provide copies of the final 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 14 of 15
17. Appendix B Technical Data Schedule Form The Tenderer shall supply the following information and guaranteed performance thereof. a Does the Rectifier Unit Control & Protection System fully comply with this Specification? YES/NO b. Type of Cubicle construction c. Height of Cubicle (mm) d. Width of Cubicle (face with Local Control Panel) (mm) e. Depth of Cubicle (mm) f. Type of mounting g. Weight of Cubicle (fitted out) (kg) h. Terminal strips total spare terminals i. Is a copy of the proposed testing procedure attached? YES / NO PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 15 of 15