Ormazabal pfu48/27 Instruction manual

LIB
pfu for large-sized
applications
Prefabricated ground-level enclosure
General instructions
IG-262-EN, versión 02, 26/04/2018

In view of the constant evolution in standards and design, the characteristics of the elements contained in this manual are subject
to change without prior notice. These characteristics, as well as the availability of components, are subject to confirmation by
Ormazabal.
CAUTION!
When medium-voltage equipment is operating, certain components are live, other parts may be in movement and some may
reach high temperatures. Therefore, the use of this equipment poses electrical, mechanical and thermal risks.
In order to ensure an acceptable level of protection for people and property, and in compliance with applicable environmental
recommendations, Ormazabal designs and manufactures its products according to the principle of integrated safety, based on
the following criteria:
• Elimination of hazards wherever possible.
• Where elimination of hazards is neither technically nor economically feasible, appropriate protection functions are
incorporated in the equipment.
• Communication about remaining risks to facilitate the design of operating procedures which prevent such risks,
training for the personnel in charge of the equipment, and the use of suitable personal protective equipment.
• Use of recyclable materials and establishment of procedures for the disposal of equipment and components so
that once the end of their service lives is reached, they are duly processed in accordance, as far as possible, with the
environmental restrictions established by the competent authorities.
Consequently, the equipment to which the present manual refers complies with the requirements of section 11.2 of Standard
IEC 62271-1. It must therefore only be operated by appropriately qualified and supervised personnel, in accordance with the
requirements of standard EN 50110-1 on the safety of electrical installations and standard EN 50110-2 on activities in or near
electrical installations. Personnel must be fully familiar with the instructions and warnings contained in this manual and in other
recommendations of a more general nature which are applicable to the situation according to current legislation[1].
The above must be carefully observed, as the correct and safe operation of this equipment depends not only on its design but also
on general circumstances which are in general beyond the control and responsibility of the manufacturer. More specifically:
• The equipment must be handled and transported appropriately from the factory to the place of installation.
• All intermediate storage should occur in conditions which do not alter or damage the characteristics of the equipment
or its essential components.
• Service conditions must be compatible with the equipment rating.
• The equipment must be operated strictly in accordance with the instructions given in the manual, and the applicable
operating and safety principles must be clearly understood.
• Maintenance should be performed properly, taking into account the actual service and environmental conditions in
the place of installation.
The manufacturer declines all liability for any significant indirect damages resulting from violation of the guarantee, under any
jurisdiction, including loss of income, stoppages and costs resulting from repair or replacement of parts.
Warranty
The manufacturer guarantees this product against any defect in materials and operation during the contractual period. In the
event that defects are detected, the manufacturer may opt either to repair or replace the equipment. Improper handling of this
equipment and its repair by the user shall constitute a violation of the guarantee.
Registered Trademarks and Copyrights
All registered trademarks cited in this document are the property of their respective owners. The intellectual property of this manual
belongs to Ormazabal.
[1] For example, in Spain the “Regulation on technical conditions and guarantees for safety in high-voltage electrical installations” – Royal Decree
337/2014 is obligatory.

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General instructions
pfu for large-sized applications
Contents
Contents
1. Description and main characteristics.......................4
2. Standards applied......................................................5
3. Main components ......................................................6
3.1. Indoor switchgear ...........................6
3.2. Prefabricated concrete enclosure .............6
4. Normal service conditions.........................................7
5. Ratings ........................................................................8
5.1. Mechanical characteristics ...................8
6. Handling .....................................................................9
6.1. Handling of enclosures with separate body
and tank .....................................9
6.1.1. Handling the tank...........................10
6.1.2. Handling of bodies with four DEHA
anchors.....................................11
6.1.3. Handling of bodies with eight DEHA
anchors.....................................12
6.2. Handling of enclosures with monoblock
body and tank ..............................14
6.2.1. Handling of enclosures with four DEHA
anchors.....................................14
6.2.2. Handling of enclosures with eight DEHA
anchors.....................................16
6.3. Handling the roof ...........................17
6.3.1. Covers with four threaded inserts............17
6.3.2. Covers with eight threaded inserts ..........18
7. Transport ..................................................................19
7.1. Road haulage ...............................19
8. Installation ...............................................................20
8.1. Receiving the equipment ...................20
8.2. Location ....................................20
8.3. Planning....................................20
8.4. Preparing the ground .......................21
8.4.1. Excavation drawings ........................21
8.4.2. Safety recommendations....................21
8.4.3. Levelling process ...........................22
8.5. Assembly process for enclosures with
separate body and tank......................24
8.6. Earth connection ...........................24
8.6.1. Protective earthing circuit. ..................25
8.6.2. Operational earthing circuit .................25
8.7. Cable connections ..........................25
9. Maintenance.............................................................26
10. Environmental information ....................................27
10.1. Recyclability ................................27

IG-262-EN versión 02; 26/04/2018
4
Description and main characteristics General instructions
pfu for large-sized applications
1. Description and main characteristics
Ormazabal pfu prefabricated enclosures for large-sized
applications are ground-level concrete enclosures with
Ormazabal medium-voltage switchgear, indoor switching,
for distribution networks up to 40.5 kV.
The enclosures are formed by reinforced concrete panels
connected by mechanical joints to make up a self-
supporting enclosure with sucient structural capacity to
withstand the stresses they are subjected to throughout
their working life, including handling, installation and
service.
This general instructions document is only fully valid
if it is interpreted along with the particular order
instructions, which include, among others, information
regarding weight, excavation details and detailed
handling instructions.
In the event of contradiction between this general
instructions document and the specic order
instructions, the latter will prevail over the former.

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General instructions
pfu for large-sized applications
Standards applied
2. Standards applied
The pfu meets the design requirements set out in Standard
IEC 62271-202 (high voltage/low voltage prefabricated
transformer substations) and applicable regulations.
For other standards, specications or regulations,
check with Ormazabal.

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6
Main components General instructions
pfu for large-sized applications
3. Main components
[2] Number of pedestrian access doors in accordance with the pfu conguration.
The solutions based on Ormazabal pfu enclosures have
two main elements:
• Indoor switchgear.
• Prefabricated concrete enclosure.
3.1. Indoor switchgear
The electrical equipment is mounted in the enclosure,
anchored to it, and may be made up of one or several of the
following elements:
• SF6fully gas-insulated medium voltage switchgear up to
40.5 kV.
• Medium voltage/low voltage full dielectric liquid-lled
distribution transformers.
• Low voltage switchgear.
• Medium and low voltage interconnections.
• Other control, metering and protection equipment.
• Interconnections between control, metering and
protection equipment.
For further information on these products, contact
Ormazabal for the relevant General Instructions.
3.2. Prefabricated concrete enclosure
The prefabricated enclosure is made up of, amongst others,
the following elements:
• Prefabricated concrete tank.
• Prefabricated concrete body. Formed by reinforced
concrete panels, mechanically attached.
• Prefabricated removable concrete cover.
• Prefabricated concrete raised oor.
• Dielectric liquid collection pit (optionally, re barrier
based on a bed of pebbles).
• Pedestrian access door[2] (clear opening measuring 900
x 2100 mm), hinged 180º on the outside wall. The door is
tted with a lock with two anchor points and a holding
pin to prevent unwanted closing (optionally, anti-panic
opening mechanism).
• Transformer area access door[2] (clear opening measuring
1260 x 2100 mm).
• Input and output grilles for natural ventilation.
• Blanked holes for cable input and output (cable access
orices 200 mm in diameter).
• Earthing protection switch box (metal part), and,
optionally, service switch box (neutral).
• Lighting and auxiliary services (optional).
The cable pit is made up of the tank (1) and the raised oor
(3).
1Tank
2Body
3Raised oor
4Cover
5Personnel access door
6Distribution transformer access door
7Ventilation grilles
8Cable access
Figure 3.1. pfu main components

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General instructions
pfu for large-sized applications
Normal service conditions
4. Normal service conditions
The pfu is designed for use in normal service conditions in
accordance with Standard IEC 62271-1.
In the enclosure, it is understood that normal indoor service
conditions in accordance with Standard IEC 62271-1 prevail.
Installation Outdoor
Solar radiation 1000 W/m2
Pollution due to corrosive and/or ammable gases Level II (medium)
Vibrations due to seismic movements or caused by
external causes
Negligible
Wind speed < 34 m/s
Table 4.1. Normal service conditions

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Ratings General instructions
pfu for large-sized applications
5. Ratings
5.1. Mechanical characteristics
The dimensions of pfu for large applications may vary
within the following ranges: Check the order documentation for more detailed
information. If further information is required, check
with Ormazabal.
Length [mm]
Minimum 4500
Maximum 8790
Width [mm]
Minimum 2500
Maximum 3300
Total maximum height [mm] 4515 *
Tank height [mm]
Minimum 600
Maximum 1000
Maximum weight of the tank [kg] 15000
Maximum weight of the body [kg] 33750
Total maximum weight** [kg] 48750
* Height may be limited by maximum tunnel dimensions in road
transport. Please check with Ormazabal.
** Weight of the empty enclosure, without switchgear.
Table 5.1. pfu dimensions variation ranges
The table below shows a series of possible variants as an
example:
pfu-
48/27
pfu-
60/27
pfu-
66/27
pfu-
72/27
pfu-
80/27
pfu-
85/27
Internal dimensions
Length [mm] 4820 6020 6620 7220 8020 8520
Width [mm] 2668 2668 2668 2668 2668 2668
Height [mm] 3030 3030 3030 3030 3030 3030
External dimensions
Length [mm] 5152 6440 7040 7640 8440 8940
Width [mm] 3000 3000 3000 3000 3000 3000
Total height [mm] 4515 4515 4515 4515 4515 4515
Visible height [mm] 3302 3302 3302 3302 3302 3302
Total weight [kg] 31,081 36,625 38,890 42,575 46,570 48,750
Given the exibility provided by the production
system used, not all the possible combinations of
dimensions (length, width and height) can be shown.
Check with Ormazabal to determine the feasibility of
other dimensions.

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General instructions
pfu for large-sized applications
Handling
6. Handling
The pfu comes in a wide range of dimensions and
weights. In consequence, the tools and equipment
necessary for handling and the detailed instructions
may vary from those shown in this section.
Check in advance with Ormazabal in order to carry
out a detailed study of the pfu handling procedure on
site.
Before handling any element, be sure to check the
weight to be handled, the strength of the lifting
equipment (slings, chains, lifting beams, eyebolts, etc.)
and the capacity of the crane.
The pfu for large-sized applications can be supplied in two
dierent ways, in accordance with the dimensions and
weight, among other factors:
• Enclosure with separate tank and body: the enclosure
is supplied in three concrete pieces which are assembled
on site: a bottom tank, a central body and a cover, which
closes the assembly at the top. The central body is made
up of prefabricated reinforced concrete panels which
have been mechanically attached.
• Enclosure with monoblock tank and body: the central
body and the tank are mechanically attached, forming a
block. The cover closes the top of the enclosure.
The instructions to handle pfu are described below. Each
prefabricated enclosure variant has a specic section with
the corresponding instructions:
• Instructions for enclosures with separate body and tank,
in section 6.1.
• Instructions for enclosures with monoblock body and
tank, in section 6.2.
• Instructions for handling the cover are set out in section
6.3.
6.1. Handling of enclosures with separate body and tank
The pfu has DEHA-type round-head anchors to ensure
correct handling using lifting beams, slings and suitable
hooks for optimally balanced lifting.The cover has threaded
inserts. The tank and body are handled separately.
Follow the instructions in section 6.1.1to handle the tank.
In accordance with the dimensions, there are bodies with
four or eight DEHA anchors. Follow the instructions in
section 6.1.2to handle the bodies with four anchors. Follow
the instructions in section 6.1.3to handle the bodies with
eight anchors. Follow the instructions in section 6.3to
handle the cover.
The following tools and equipment are required in order to
handle the enclosure with separate tank and body tank and
body.
The amounts of each tool or equipment required will
vary in accordance with the detailed handling study.
1Top slings
2Lifting beams (Modulift type or adjustable length)
2.1 Larger lifting beam shackle
2.2 Smaller lifting beam shackle
3Bottom slings or chains*
4Universal-head hooks (DEHA KA-type**)
* Slings or chains, in accordance with the detailed study of the handling
process.
** The tank and body may require dierent universal head hooks.
Figure 6.1. Equipment and tools required

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Handling General instructions
pfu for large-sized applications
6.1.1. Handling the tank
The information presented is only general, not detailed.
Check in advance with Ormazabal to determine the
details for the handling tools and equipment.
Two DEHA-type anchors are set out on each long side of
the tank.
1DEHA-type anchors
Figure 6.2. Layout of DEHA anchors
Proceed as follows:
1. Make sure the tools and equipment shown in Figure 6.3
are available, ensuring the larger shackle of the lifting
beam is joined to the top slings. The smaller shackle is
attached to the bottom slings or chains. Hook the top
slings on the crane hook.
1Top slings
2Lifting beam
2.1 Larger lifting beam shackle
2.2 Smaller lifting beam shackle
3Bottom slings or chains*
4Universal-head hooks (DEHA KA-type**)
* Slings or chains, in accordance with the detailed study of the handling
process.
** The tank and body may require dierent universal head hooks.
Figure 6.3. Fastening tools set
2. Couple the four universal-head hooks to the tank's
DEHA-type anchors, as shown in Figure 6.4.
Figure 6.4. Correct coupling method using DEHA hooks
3. Lift the pfu tank with the crane and position in the pit
provided for this purpose (see the individual excavation
plan for each installation).
Figure 6.5. Lifting and positioning the pfu tank
4. Once the pfu tank is in place, uncouple the universal-
head hooks from the tank's DEHA anchors.