Powell PowlVac 1200A User manual

01.4IB.51000C
PowlVac®Metal-Clad Switchgear
5kV & 15kV, 1200A, 2000A, 3000A, & 4000A Force Cooled
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PowlVac® Metal-Clad Switchgear
5kV & 15kV
01.4IB.51000C
Contact Information
Powell Electrical Systems, Inc.
powellind.com
[e-mail]
Service Division
PO Box 12818
Houston, Texas 77217-2818
Tel: [phone]
Fax: [phone]
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01.4IB.51000C
Signal Words
As stated in ANSI Z535.4-2007, the signal word is
a word that calls attention to the safety sign and
designates a degree or level of hazard seriousness.
The signal words for product safety signs are
“Danger”, “Warning”, “Caution” and“Notice”.
These words are defined as:
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury.
!
DANGER
!
WARNING
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
!
CAUTION
CAUTION, used with the safety alert symbol,
indicates a hazardous situation which, if not
avoided, could result in minor or moderate
injury.
CAUTION, used without the safety alert
symbol, is used to address practices not
related to personal injury.
CAUTION
NOTICE
NOTICE is used to address practices not related
to personal injury.
Qualified Person
For the purposes of this manual, a qualified
person, as stated in NFPA 70E®, is one who has
skills and knowledge related to the construction
and operation of the electrical equipment and
installations and has received safety training to
recognize and avoid the hazards involved. In
addition to the above qualifications, one must also
be:
1. trained and authorized to energize,
deenergize, clear, ground, and tag circuits
and equipment in accordance with
established safety practices.
2. trained in the proper care and use of
personal protective equipment (PPE)
such as rubber gloves, hard hat, safety
glasses or face shields, flash clothing, etc.,
in accordance with established safety
practices.
3. trained in rendering first aid if necessary.
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5kV & 15kV
01.4IB.51000C
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01.4IB.51000C
Contents
Ch 1 General Information ................................................................................................1
A. Scope ...............................................................................................................................................................2
B. purpoSe ............................................................................................................................................................2
c. InStructIon BulletInS AvAIlABle electronIcAlly ....................................................................................................2
D. ASSocIAteD BulletInS ..........................................................................................................................................3
Ch 2 Safety .......................................................................................................................4
A. SAfe Work conDItIon .........................................................................................................................................4
B. SAfety GuIDelIneS ...............................................................................................................................................4
c. GenerAl ............................................................................................................................................................5
D. SpecIfIc .............................................................................................................................................................5
e. SAfety lABelS ....................................................................................................................................................5
Ch 3 Equipment Description ............................................................................................6
A. GenerAl ............................................................................................................................................................6
B. DImenSIonS ........................................................................................................................................................7
1) One-high Construction ..........................................................................................................................................................7
2) Two-high Construction .......................................................................................................................................................... 7
c. prImAry compArtment ........................................................................................................................................7
D. SeconDAry compArtment ....................................................................................................................................8
e. rAtInGS .............................................................................................................................................................9
f. lIGhtInG ImpulSe WIthStAnD (BIl) .......................................................................................................................9
G. cIrcuIt BreAkerS ............................................................................................................................................. 10
h. cIrcuIt BreAker rAckInG mechAnISm ................................................................................................................. 11
I. SAfety InterlockS AnD provISIonS ..................................................................................................................... 12
1) Key Interlocks ..........................................................................................................................................................................12
2) Circuit Breaker Compartment Safety Provisions ...........................................................................................................12
J. AuxIlIAry compArtmentS ................................................................................................................................. 13
k. AntI-conDenSAtIon heAterS ............................................................................................................................ 13
l. voltAGe (potentIAl) trAnSformer (rollout cArrIAGe) ....................................................................................... 14
m. fuSe DISconnectInG DevIce (rollout cArrIAGe) .................................................................................................. 14
n. current trAnSformerS (throuGh-type) ............................................................................................................ 15
o. mAIn BuS, mAIn BuS tApS, AnD GrounDS .......................................................................................................... 15
p. prImAry DISconnect DevIceS AnD SupportS ....................................................................................................... 16
Q. lIGhtInG ......................................................................................................................................................... 16
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ii
01.4IB.51000C
PowlVac® Metal-Clad Switchgear
5kV & 15kV
Contents
Ch 4 Installation .............................................................................................................17
A. GenerAl ......................................................................................................................................................... 17
B. receIvInG ........................................................................................................................................................ 17
c. hAnDlInG ....................................................................................................................................................... 17
D. StorAGe ......................................................................................................................................................... 18
e. prepArAtIon of floor-AnchorInG ..................................................................................................................... 19
f. poSItIonInG the metAl-clAD SWItchGeAr ........................................................................................................... 20
1) Drawings and Diagrams .......................................................................................................................................................20
G. Door AlIGnment ............................................................................................................................................. 21
h. the removABle element ................................................................................................................................... 22
I. GrounDInG ..................................................................................................................................................... 23
J. connectIonS ................................................................................................................................................... 24
k. mAIn BuS ASSemBly AnD InSulAtIon ................................................................................................................... 25
1) Main Bus Joint Insulation ....................................................................................................................................................25
2) Wrapping of Joints ................................................................................................................................................................26
3) Applying Bus Insulating Boots ...........................................................................................................................................29
4) Incoming Power Connections ............................................................................................................................................29
5) Cleaning Bus Insulation .......................................................................................................................................................29
l. prImAry cABleS ............................................................................................................................................... 29
m. InSulAtInG prImAry cABle termInAtIonS ............................................................................................................. 30
n. GrounD fAult current trAnSformerS (WInDoW-type) ....................................................................................... 31
o. control cABleS .............................................................................................................................................. 32
p. SurGe protectIon ........................................................................................................................................... 32
Q. roof entrAnce BuShInG ................................................................................................................................... 32
r. BuS Duct entry .............................................................................................................................................. 33
S. AuxIlIAry DevIce rollout cArrIAGe ................................................................................................................... 34
1) Control Power Transformer Rollout ..................................................................................................................................34
2) Fuse Rollout ............................................................................................................................................................................34
Ch 5 Operation ...............................................................................................................35
A. GenerAl ......................................................................................................................................................... 35
B. InSertInG the removABle element Into the compArtment .................................................................................... 35
1) Inserting the Circuit Breaker Into the Lower Compartment (One-High Design) ....................................................36
2) Inserting the Circuit Breaker Into the Upper Compartment (Two-High Design) ...................................................36
c. rAckInG mechAnISm ........................................................................................................................................ 37
D. rAckInG proceDure (mAnuAl) .......................................................................................................................... 40
1) Inserting the Circuit Breaker to the
Test/Disconnected Position .................................................................................................................................................40
2) Inserting the Circuit Breaker to the Connected Position ..............................................................................................41
3) Removing the Circuit Breaker from the
Connected Position ...............................................................................................................................................................42
4) Removing the Circuit Breaker from the
Test/Disconnected Position out of the Circuit Breaker Compartment ......................................................................43
e. rAckInG proceDure (electrIcAl) ....................................................................................................................... 43
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01.4IB.51000C
Contents
f. electrIcAl operAtIon ....................................................................................................................................... 44
G. ShutterS ........................................................................................................................................................ 44
h. removABle element poSItIon Interlock (optIonAl) ............................................................................................. 45
I. floor pAn ...................................................................................................................................................... 45
J. truck-operAteD cell SWItch (toc) (optIonAl) ................................................................................................ 46
k. mechAnISm-operAteD cell SWItch (moc) (optIonAl) ........................................................................................ 46
l. SeconDAry DISconnect DevIce .......................................................................................................................... 47
m. Dummy removABle element ............................................................................................................................. 48
n. GrounD AnD teSt DevIce .................................................................................................................................. 49
o. teSt AnD InSpectIon ......................................................................................................................................... 49
Ch 6 Maintenance ..........................................................................................................51
A. GenerAl ......................................................................................................................................................... 51
B. overAll mAIntenAnce proceDureS .................................................................................................................... 51
1) Equipment ...............................................................................................................................................................................52
2) Bus Insulation .........................................................................................................................................................................52
3) Mechanisms ............................................................................................................................................................................52
4) Primary Disconnect Device Contacts ...............................................................................................................................52
5) Disconnecting Contacts .......................................................................................................................................................52
6) Control Contacts ....................................................................................................................................................................53
7) Secondary Wiring ..................................................................................................................................................................53
8) Mechanical Parts ...................................................................................................................................................................53
9) Ventilation ...............................................................................................................................................................................53
10) Battery and Charging Equipment .....................................................................................................................................53
11) Hardware .................................................................................................................................................................................53
12) Heaters .....................................................................................................................................................................................53
13) Testing ......................................................................................................................................................................................54
14) Doors ........................................................................................................................................................................................54
15) Interlocks .................................................................................................................................................................................55
16) Actuators .................................................................................................................................................................................55
17) 4000A Versions Only .............................................................................................................................................................55
c. ABnormAl conDItIonS ..................................................................................................................................... 55
Ch 7 Recommended Renewal Parts and Repair Procedure ...........................................57
A. orDerInG InStructIonS ..................................................................................................................................... 57
B. recommenDeD reneWAl pArtS .......................................................................................................................... 57
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iv
01.4IB.51000C
PowlVac® Metal-Clad Switchgear
5kV & 15kV
Figures
Figure 1 Metal-Clad Switchgear Line-up .....................................................................6
Figure 2 One High Basic Construction .........................................................................7
Figure 3 Two-High Basic Construction .........................................................................7
Figure 4 Interior Metal-Clad Switchgear (Lower Compartment) .............................10
Figure 5 Front Cover of Circuit Breaker .....................................................................10
Figure 6 Circuit Breaker Cover Removed ...................................................................13
Figure 7 Unit Space Heater ........................................................................................13
Figure 8 Voltage Transformer and Rollout Carriage .................................................14
Figure 9 Control Power Transformer (Rollout Carriage) ...........................................14
Figure 10 Lifting Method for Switchgear .....................................................................18
Figure 11 Recommended Floor ....................................................................................20
Figure 12 Anchoring of Units with Channel Base ........................................................21
Figure 13 Circuit Breaker with Shipping Bracket .........................................................22
Figure 14 Auxiliary Device with Shipping Bracket ......................................................22
Figure 15 Ground Bus Splice Plate Connection ...........................................................24
Figure 16 Placing the Boot over the Joint ....................................................................25
Figure 17 Boot Installation ..........................................................................................26
Figure 18 Insulation of Bus Bar ....................................................................................27
Figure 19 Single Bus Bar Connection Joint ..................................................................27
Figure 20 Double Bus Bar Connection Joint ................................................................28
Figure 21 Tee Connection Joint ....................................................................................28
Figure 22 Cable Termination Joint ...............................................................................30
Figure 23 Bar-Type Current Transformer Joint Insulation ..........................................31
Figure 24 Roof Bushing ................................................................................................33
Figure 25 Angle Shipping Bracket ................................................................................34
Figure 26 Recommended Method for Lifting Circuit Breaker to Upper Cell ...............38
Figure 27 Closed Door Racking ....................................................................................39
Figure 28 Secondary Disconnecting Device ................................................................40
Figure 29 Standard Circuit Breaker in Test Position ....................................................41
Figure 30 Pushing Manual Trip Operator & Accessing Racking Drive Shaft ...............41
Figure 31 Racking the Standard Circuit Breaker .........................................................42
Figure 32 Anti-Rollout Latch ........................................................................................43
Figure 33 Shutters ........................................................................................................44
Figure 34 Position Interlock .........................................................................................45
Figure 35 Typical Compartment Door with Closed Door or
Through-Door Provisions ............................................................................46
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01.4IB.51000C
Tables
Table A Standard Dimensions ...........................................................................................8
Table B Ratings of Medium Voltage PowlVac® Metal-Clad Switchgear ...........................9
Table C Bolt Torque Values ..............................................................................................25
Table D Bus Wrapping Components ...............................................................................26
Table E Insulation of Bus Bar ...........................................................................................27
Table F Insulation of Single Bus Bar Connection Joint ...................................................27
Table G Insulation of Double Bus Bar Connection Joint .................................................28
Table H Insulation of Tee Connection Joint ....................................................................28
Table I Cable Termination Joint ......................................................................................30
Table J Bar-Type Current Transformer Joint Insulation ..................................................31
Table K Pothead, Bushing, or Terminator .......................................................................33
Table L Rated Control Power Voltages & Ranges for Circuit Breakers ............................50
Table M Accessories .........................................................................................................58
Table N Lift Trucks ............................................................................................................59
Figures
Figure 36 Lower Mechanism-Operated Cell Switch (MOC) and
Operating Mechanism .................................................................................47
Figure 37 Upper Mechanism-Operated Cell Switch (MOC) and
Operating Mechanism .................................................................................48
Figure 38 4000A Force Cooled Section Views ..............................................................56
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PowlVac® Metal-Clad Switchgear
5kV & 15kV
01.4IB.51000C
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