ENGINEERING STANDARD - CMDG

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ENGINEERING STANDARDMotor Control CentresDocument:GRC-ES004Revision:2REVISION HISTORYRevDateDescriptionPrepared ByApproved By125/08/2011First IssueJ. HickeyC. Swanton221/04/2017Revised and UpdatedB. JamesC. SwantonCopyright 2016 Gladstone Regional Council. This document is confidential and may contain information proprietary toGladstone Regional Council. The disclosure, copying or taking action in reliance on or distribution of this document orany information it contains by anyone other than those authorised to do so, in writing, by Gladstone Regional Council isprohibited. This document reflects the requirements of Gladstone Regional Council and may not represent the opinionsof the author of this document.

ENGINEERING STANDARDGRC-ES004 – Motor Control CentresTABLE OF CONTENTS1PURPOSE . 32SCOPE . 33RESPONSIBILITIES. 34DEFINITIONS . 45REFERENCE DOCUMENTS . 55.15.25.35.46TECHNICAL REQUIREMENTS. 156.167GRC Engineering Standards. 5GRC Standard Drawings . 5Australian Standards . 5Acts and Regulations . 5General. 6Construction . 6Busbars . 7Earthing of Assemblies . 8Switchgear Assemblies . 8Control and Indication Devices . 11PLC Section. 13Cable Zones . 13Gland Plates . 13Cable Entry and Termination . 14Identification Labels . 15Bolts and Nuts . 15Hinges . 15Handles and Latching Mechanisms . 16Gaskets and Seals. 16Accessories . 16INSPECTION AND TESTING . 167.17.27.37.4Verification Testing . 16Routine Testing. 16Test Certificates . 17Witnessing . 178TRANSPORTATION AND STORAGE . 179PAINTING AND SURFACE PROTECTION . 1710MANUALS AND DRAWINGS . 1811DATA SHEETS . 18Revision 2, 21 April 2017Page 2 of 18

ENGINEERING STANDARDGRC-ES004 – Motor Control Centres1PURPOSEThe purpose of this Engineering Standard is to describe the requirements for the design,manufacture, supply, testing and delivery to site of 415V Motor Control Centre switchboards forGladstone Regional Council. This Engineering Standard shall be read in conjunction with theattached Motor Control Centre data sheet.2SCOPEThis Engineering Standard is applicable to all 415V Motor Control Centre switchboards, for indoorand outdoor areas supplied for use at Gladstone Regional Council sites, where the primary supplyis 415V three phase.3RESPONSIBILITIESAll persons involved in the purchasing, design, fabrication and supply of 415V Motor ControlCentres for use on any GRC site shall comply with this Engineering Standard.Any variations proposed that are contrary to the requirements of this Engineering Standard shall bespecifically identified and referred to GRC, in writing, for approval.The Purchaser shall complete the attached Motor Control Centre data sheet for each switchboardrequired.Revision 2, 21 April 2017Page 3 of 18

ENGINEERING STANDARDGRC-ES004 – Motor Control Centres4DEFINITIONSTermDefinitionCouncilGladstone Regional Council or its nominated representative or agent.GRCGladstone Regional Council or its nominated representative or agent.HzHertzLVManufacturerLow Voltage, Exceeding 32VAC or 115VDC but not exceeding 1000VAC or1500VDC.The corporation or business that manufactures and/or assembles theequipment described by this Engineering Standard.MCBMiniature Circuit BreakerMCCMotor Control CentreMCCBMoulded Case Circuit BreakerMEN SystemPurchaserMultiple Earthed Neutral. A system of earthing in which the parts of anelectrical installation required to be earthed in accordance with AS/NZS 3000are connected to the general mass of earth and, in addition are connectedwithin the electrical installation to the neutral conductor of the supply system.The individual or corporation responsible for purchasing the equipmentdescribed by this Engineering Standard on behalf of GRC.RCBOResidual current Circuit Breaker with Overload protection.SpecifierAny individual specifying equipment for use in electrical installations on a GRCsite.Superintendent Person authorised to act on behalf of GRC with respect to the Contract works.SupplierThe individual or corporation with whom GRC enters an agreement topurchase the equipment described by this Engineering Standard. Note that insome instances, the Supplier may also be the Manufacturer.TOLThermal OverloadRevision 2, 21 April 2017Page 4 of 18

ENGINEERING STANDARDGRC-ES004 – Motor Control Centres5REFERENCE DOCUMENTSAll equipment shall be designed, manufactured and tested in accordance with the latest edition ofthe following GRC Engineering Standards, Australian Standards, Acts and Regulations.5.1GRC Engineering StandardsStandardTitleGRC-ES001Electrical WorkGRC-ES002Preferred Electrical ComponentsGRC-ES005Light & Power Distribution BoardsGRC-ES008Equipment Identification5.2GRC Standard DrawingsDrawingTitleGRC-ED-010Typical Schematic 4kW DOL StarterGRC-ED-011Typical Schematic 4-40kW Soft StarterGRC-ED-012Typical Schematic 40kW VSDGRC-ED-013Typical MCC DB, UPS, 24VDC Power Supply5.3Australian StandardsStandardTitleAS 1319Safety Signs for Occupational EnvironmentAS 2700Colour Standards for General PurposesAS/NZS 3000Electrical Installations (Australian/New Zealand Wiring Rules)AS/NZS 3008Electrical Installation – Selection of CablesAS/NZS 3017Electrical Installations – Testing and Inspection GuidelinesAS/NZS 3820Essential Safety Requirements for Electrical EquipmentAS 60529Degrees of Protection Provided by Enclosures (IP Code)AS/NZS 60947Low-voltage Switchgear and ControlgearAS/NZS 61439Low Voltage Switchgear and Controlgear AssembliesAS 62103Electronic Equipment for Use in Power InstallationsAS 60044Instrument Transformers5.4Acts and RegulationsTitleElectrical Safety Act 2002Electrical Safety Regulation 2002Work Health and Safety Act 2001Work Health and Safety Regulation 2011Revision 2, 21 April 2017Page 5 of 18

ENGINEERING STANDARDGRC-ES004 – Motor Control Centres6TECHNICAL REQUIREMENTS6.16.1.1GeneralQuality AssuranceThe Manufacturer shall have an integrated quality assurance system in place at the locationswhere the motor control centres are designed, manufactured and assembled. The system shall be‘third party accredited’ to AS/NZS ISO 9001:2000 and frequently audited for compliance. TheManufacturer shall provide documentation proving any claims made with respect to the above ifrequested by the Purchaser.6.1.2Prohibited MaterialsComponents that contain asbestos, mercury, cadmium, PCB’s, silica gel containing the indicatingagent cobalt chloride or any other products either known to or suspected of having carcinogenic orother detrimental long or short term effects on the health of personnel if they are inhaled, ingestedor otherwise contacted during normal and reasonable use are not permitted in electrical equipmentto be used on the Purchaser’s site.This requirement shall apply to all fabrication tools and equipment used that could leave dustparticles or other residues inside the assemblies as well as components used in the construction ofthe MCC’s and associated components covered by this Standard.6.1.3Standardisation of Parts and EquipmentThe Supplier shall select all components, parts and equipment used in the construction andfabrication of the switchboard from the Preferred Electrical Components List GRC-ES002.If the Supplier wishes to utilise items not included in the preferred components list, approval shallbe obtained from GRC in accordance with the requirements of GRC-ES002.6.1.4Service ConditionsThe switchboard and associated equipment shall be designed to operate continuously, 24 hoursper day, 365 days per year.The switchboard shall be capable of continuously carrying the rated current at rated frequencywithout exceeding allowable temperatures, in accordance with the Manufacturers type testedrating.All components and equipment within the Motor Control Centre shall have an ambient temperaturerating of not less than 55 C. The thermal design shall be such that the maximum temperaturewithin the switchboard when operating under an ambient temperature of 45 C shall not exceed55 C. The thermal design shall be based on natural heat dissipation. Ventilation openings shallnot be used unless specified.6.2Constructiona)The switchboard shall be of free standing, metal-clad type and shall be built to the Supplier’slatest verified design in accordance with AS/NZS 61439, the Drawings and Data Sheet.b)The switchboard shall consist of modules arranged in vertical sections or tiers. The tiersshall be configured in an arrangement suitable for free standing installation on a concretepad for outdoor installation and plinth mounted for indoor installation. The switchboard shallprovide front access and front connection unless otherwise specified. Doors shall open 120º.Revision 2, 21 April 2017Page 6 of 18

ENGINEERING STANDARDGRC-ES004 – Motor Control CentresEscutcheon plates shall be provided to effectively shroud all live parts in panels when theaccess door is open.c)Individual functional units shall be of demountable or withdrawable design and shall be auniform width and depth with a combination of modular heights permitting new modules to beinstalled and interchange of existing modules post installation.d)The switchboard height shall not exceed 2200mm.e)The various compartments of the switchboard shall be designed and tested for arc faultcontainment in accordance with AS/NZS 61439.1 Appendix ZD.f)Equipment and terminals shall be readily accessible in the cubicles and shall require aminimum of disturbance of associated and adjacent equipment for access.g)Form of internal separation to AS/NZS 61439 shall be Form 3B. Form 3Bih will not beaccepted.h)Terminals, busbars and any components carrying voltages greater than extra low voltageshall be protected against accidental contact by personnel to an IP rating of IP2X to AS60529. This shall be achieved by fitting proprietary shrouds or fabricating clear barriers.Shrouds shall be used on cable terminals in the cable zones.i)Test certificates for the assemblies shall be submitted for review before constructioncommences.j)The complete switchboard shall be vermin and insect proof.k)Facilities shall be provided for lifting transportable sections without distortion.6.2.1Indoor SwitchboardsSwitchboards designated on the Data Sheet as indoor service, which will be installed within adedicated electrical switchroom building shall be constructed from powder coated mild steel atleast 1.6mm thick and shall have a minimum degree of protection of IP52.6.2.2Outdoor SwitchboardsSwitchboards designated on the Data Sheet as outdoor service, which will be installed external toa building or within a corrosive and/or wet environment shall be constructed from powder coated316 stainless steel at least 1.6mm thick or marine grade aluminium at least 3mm thick, and shallhave a minimum degree of protection of IP56. In addition, outdoor switchboards shall alsoincorporate the following features:a)Full height outer doors covering all functional units and controls. Doors shall be providedwith lift of pintle hinges. Hinges shall permit the door to move through an arc of at least 120 .b)Outer doors shall be lockable and fitted with a stainless steel 3 point locking mechanism, witheither 1 or 3 Dirak 207-9295 Swing Handles or equivalent with lock No. 92285.c)Roof heat shields mounted on 50mm C section supports.d)Side heat shield mounted on 20mm stand-offs.6.3Busbars6.3.1Main BusbarsThe busbar system shall consist of a horizontal 3 phase set of rectangular hard drawn, highconductivity copper bars, air insulated and supported by suitable insulators. The busbars shall bebolted with high tensile, corrosion resistant steel bolts. Bolted busbar joints shall be tensioned inaccordance with the manufacturer's recommendations. Flexible busbar connections are notRevision 2, 21 April 2017Page 7 of 18

ENGINEERING STANDARDGRC-ES004 – Motor Control Centresacceptable. Each section of busbar shall be colour coded at regular intervals and at terminationpoints. Busbars shall be continuously rated for the maximum full load current per phase.The busbars and support system shall be a tested and verified design able to withstand theprospective fault level as indicated on the Data Sheet. A physical barrier shall isolate live busbarsfrom other sections.Busbar temperature rise at full load shall be limited to 50 C with an ambient temperature of 40 C.Busbar temperature shall not exceed 90 C under full load conditions.6.3.2Vertical BusbarsEach tier shall have a 3 phase copper vertical busbar for the distribution of power from the mainbusbar to the individual modules. The busbar shall be designed to permit the connection ofindividual modules. The capacity of the vertical busbar shall not be less than 300A.6.3.3Neutral BusbarsA vertical neutral busbar shall be provided within each cable zone of the switchboard and shallprovide adequate connection facilities for each incoming and outgoing circuit. The neutral busbarrating shall be 100% of the phase busbar rating. The switchboard shall be designed so that effectsof eddy currents around neutral busbars are minimised.6.3.4Earth BusbarsA continuous, separate earth busbar shall be provided along the full length of the switchboard andshall provide adequate connection facilities for each incoming and outgoing circuit, with verticaldroppers in each cable zone. Connections shall be provided at each end of the earth bar for earthcables to the site earth grid.6.3.5MEN LinkA removable MEN link of full size of the neutral shall be provided. The MEN link shall be easilyaccessible in the switchboard.6.4Earthing of AssembliesAll metal components of the assemblies shall be effectively earthed. Special attention shall begiven to earthing of those components which are hinged, withdrawable or demountable.All hinged doors shall have an earthing stud. Doors with electrical equipment installed on the doorshall have an earthing cable installed from the earth stud on the door to an earth connection on thebody of the main assembly.6.56.5.1Switchgear AssembliesFunctional UnitsFunctional units shall be of demountable or withdrawable design and shall be a uniform width anddepth with a combination of modular heights permitting interchange, and shall be in accordancewith the following requirements:a)Functional units shall include equipment shown on the Drawings. All equipment shall be inaccordance with the relevant clauses of this Engineering Standard. Equipment shall bearranged within functional units to permit easy access and removal of all components withoutinterference to the structure, other components or cable entry.Revision 2, 21 April 2017Page 8 of 18

ENGINEERING STANDARDGRC-ES004 – Motor Control Centresb)Functional unit power connection to main vertical busbars shall be via clamp or springcontact devices.c)It shall not be possible to come into contact with any live wiring or components when thecircuit breaker or isolator is in the “Off” position and module door is open, without deliberatelyremoving covers. A fully insulated and shrouded installation is required.6.5.2Main Incomer SectionsThe specific requirements for the incomer sections will be shown on the Drawings. Typicalrequirements shall include:a)The main incomer section shall be equipped with a withdrawable air circuit breaker forswitchboards rated greater than 800A or an MCCB for switchboards rated 800A or less, witha certified breaking capacity not less than the specified fault level. The circuit breaker shallhave the following features:oIntegral solid state protection relay incorporating time delayed overcurrent,instantaneous overcurrent and earth fault protectionoManual spring chargeoShunt tripoManual Open PushbuttonoManual Close PushbuttonoLockable safety shuttersoIsolation Padlock facilityb)The incomer section shall incorporate a digital power meter with metering CTs to provideindication for volts, amps, watts, apparent power, power factor and voltage harmonic content.c)The incomer front panel shall have a cut away section such that the circuit breaker controlsand indication are exposed.d)The incomer section shall incorporate a surge diverter as specified on the Drawings.6.5.3Supply Authority MeteringIf required on the Drawings, the switchboard shall incorporate a provision for a separate CTchamber and a panel for external supply authority metering equipment in accordance with therequirements of the latest version of the Queensland Electricity Connection and Metering Manual.6.5.4Emergency Genera

latest verified design in accordance with AS/NZS 61439, the Drawings and Data Sheet. b) The switchboard shall consist of modules arranged in vertical sections or tiers. The tiers shall be configured in an arrangement suitable for free standing installation on a concrete pad for outdoor

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