Velatia ORMAZABAL basic pfu Series Instruction manual

LIB
pfu basic range
Prefabricated concrete enclosure,
ground-level walk-in type
General instructions
IG-032-EN, version 05, 18/06/2019

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 basic range: Prefabricated concrete
enclosure, ground-level walk-in type
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 the body ...........................9
6.2. Handling the roof ...........................13
6.2.1. pfu-3 and pfu-4 roofs . . . . . . . . . . . . . . . . . . . . . . .13
6.2.2. pfu-5 roof ..................................15
6.2.3. pfu-7 roof ..................................16
7. Transport ..................................................................18
7.1. Road transport..............................18
8. Installation ...............................................................19
8.1. Receiving the equipment ...................19
8.2. Location ....................................19
8.3. Planning....................................20
8.4. Preparing the ground .......................21
8.4.1. Excavation drawings ........................21
8.4.2. Safety recommendations....................22
8.4.3. Levelling process ...........................23
8.4.4. Sealing cable accesses ......................25
8.5. Earth connection ...........................26
8.5.1. Protective earthing circuit. ..................26
8.5.2. Operational earthing circuit .................26
8.5.3. Exterior earthing circuit .....................27
8.6. Cable connections ..........................28
8.6.1. Low-voltage auxiliary supply input ..........28
9. Maintenance.............................................................30
10. Environmental information ....................................31
10.1. Recyclability ................................31

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Description and main characteristics General instructions
pfu basic range: Prefabricated concrete
enclosure, ground-level walk-in type
1. Description and main characteristics
Ormazabal's pfu prefabricated buildings are ground-level,
walk-in type concrete enclosures with Ormazabal medium-
voltage switchgear for distribution networks up to 40.5 kV.
The buildings consist of a monoblock enclosure and a
removable roof, both prefabricated in reinforced concrete.
Buildings are self-supporting and have the structural
capacity necessary to respond to the stresses they are
subjected to throughout service life, including handling,
installation and service.

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General instructions
pfu basic range: Prefabricated concrete
enclosure, ground-level walk-in type
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, please
contact Ormazabal.

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Main components General instructions
pfu basic range: Prefabricated concrete
enclosure, ground-level walk-in type
3. Main components
[2] Number of pedestrian access doors to the transformer area in accordance with the pfu conguration.
The solutions based on Ormazabal's pfu buildings have
two main elements:
• Indoor switchgear.
• Prefabricated concrete enclosure.
3.1. Indoor switchgear
The switchgear is mounted in the enclosure, anchored to
it, and may be made up of one or several of the following
elements:
• Fully gas-insulated medium-voltage switchgear up to
40.5 kV.
• Medium-voltage/low-voltage full liquid dielectric-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 more information on these products, please contact
Ormazabal.
3.2. Prefabricated concrete enclosure
The prefabricated enclosure is made up of, amongst others,
the following elements:
• Prefabricated monoblock concrete body.
• Prefabricated removable concrete roof.
• Prefabricated concrete raised oor.
• Liquid dielectric collection trench (optionally, re barrier
based on a bed of pebbles).
• Pedestrian access door[2] (clear opening measuring
900 x 2100 mm or 1100 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 areaaccess door[2] (clear openingmeasuring
1260 x 2100 mm).
• Air input and output grilles for natural ventilation.
• Pre-punched holes for cable input and output at the
lower front and back of the enclosure (cable access
orices 200 mm in diameter).
• One 140 mm diameter hole above level 0 in the front
wall for an auxiliary low-voltage input.
• Two earthing protection switch boxes (metal part), and
an operational switch box (neutral).
• Lighting and auxiliary services (optional).
• The cable trench is made up of the bottom of the
monoblock body (1) and the raised oor (2).
1Body
2Raised oor
3Roof
4Pedestrian access doors
5Transformer area access door
6Ventilation grilles
7Cable access
Figure 3.1. pfu main components

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General instructions
pfu basic range: Prefabricated concrete
enclosure, ground-level walk-in type
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 building, it is understood that normal indoor service
conditions according to 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 basic range: Prefabricated concrete
enclosure, ground-level walk-in type
5. Ratings
5.1. Mechanical characteristics
The dimensions and weights of the pfu models are shown
below: For further information, please ask Ormazabal.
pfu-3 pfu-4 pfu-5 pfu-7
Length [mm] 3280 4460 6080 8080
Body width [mm] 2380
Roof width [mm] 2500
Total height [mm] Standard roof 3045 3240
Raised roof 3240 -
Visible height [mm] Standard roof 2585 2780
Raised roof 2780 -
Weight [kg]* 10 545 13 465 17 460 29 090
* Weight of the empty building with standard roof and ventilation for 1000 kVA.
Table 5.1. pfu dimensions and weight

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General instructions
pfu basic range: Prefabricated concrete
enclosure, ground-level walk-in type
Handling
6. Handling
6.1. Handling the body
The pfu has DEHA-type round-head anchors to ensure
correct handling using lifting beams, slings and suitable
hooks for optimally balanced lifting. The roof has threaded
inserts.
The following tools and equipment are required to handle
the body:
1Cables
235 T Lifting beam
2.1 Numbered holes for transverse balancing
3
Lower slings/chains with elongation ring and DEHA KA-type
hooks.
Sling length:
• pfu-3 and pfu-4: 5100 mm (minimum 4000 mm)
• pfu-5 and pfu-7: 5100 mm
DEHA KA-type hooks load class:
• pfu-3, pfu-4 and pfu-5: 7.5
• pfu-7: 10
Figure 6.1. Tools and equipment required
Vertical and horizontal balance must be ensured when
handling the pfu. Standard slings with extensions
should be used for the pfu and pfs buildings. For any
doubts, please ask Ormazabal.
Transformer weight limitation for handling the
pfu-7: The maximum weight of the transformers is
limited to the values shown in the gure, according to
the internal layout of the switchgear:
aConguration of two transformers at the ends of
the building
b
Conguration of two contiguous transformers at
one end (only one installed in position closest to
the centre of the building)*
c
Conguration of two contiguous transformers at
one end (only one installed in position furthest
away from the centre of the building)*
dConguration of one transformer at one end of
the building*
eConguration of two contiguous transformers at
one end of the building*
* Also includes the conguration with the transformers on
the left side
Figure 6.2. Maximum weight of transformers (in kg),
according to the arrangement of the equipment,
for handling pfu-7
Forsafetyreasons,handlingthepfu-7withtransformers
heavier than indicated is strictly forbidden.

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Handling General instructions
pfu basic range: Prefabricated concrete
enclosure, ground-level walk-in type
Two DEHA-type anchors are set out on each long side of
the body.
The body and roof can be handled together.
1DEHA-type anchors
Figure 6.3. Layout of DEHA anchors
Do this by proceeding as follows:
1. Join the tools and equipment. The lifting beam has a
series of numbered holes at the end for transverse
balancing. Table 6.1 shows the appropriate positions
for each model and the minimum height required from
the crane hook to the oor in order to lift the pfu. Hook
the lower slings/chains on the crane hook.
a. In the case of pfu-3, pfu-4 and pfu-5, join the tools
in accordance with Figure 6.4, without using the
elongation rings.
1Cables
2Lifting beam
2.1 Numbered holes for transverse balancing
3Lower slings/chains with elongation ring and DEHA KA-type
hooks
Figure 6.4. Lifting tools set for pfu-3, pfu-4 and pfu-5

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General instructions
pfu basic range: Prefabricated concrete
enclosure, ground-level walk-in type
Handling
b. In the case of pfu-7, join the tools according to
Figure 6.5, using the elongation rings.
In the case of congurations b, c, dand e(transformer
at one end) of Figure 6.2, elongation rings must
be placed on the slings on the side opposite the
transformer's location.
1Cables
2Lifting beam
2.1 Numbered holes for transverse balancing
3Lower slings/chains with elongation ring and DEHA KA-type
hooks
Figure 6.5. Lifting tools set for pfu-7
nº hole in lifting
beam
Minimum crane hook height for hoisting (m)
[mm]
pfu-3 Without transformer
or with 1 ransformer
Without switchgear 2 6160
With switchgear 3
pfu-4 Without transformer
or with 1 ransformer
Without switchgear 2 6000
With switchgear 3
pfu-5
Without transformer
or with 1 ransformer
Without switchgear 2
5500
With switchgear 3
2 transformers Without switchgear 2
With switchgear 3
pfu-7 With switchgear 3 6500
Table 6.1. Indicative recommendation of the hole number in the lifting beam for transverse balancing
Depending on the layout of the equipment inside, it
may be necessary to choose a hole adjacent to the one
recommended. Control the balance of the building
during handling operations and acting accordingly.
2. Position the lifting equipment so the end of the lifting
beam with the transverse balancing holes is on the side
of the building's metal doors.

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Handling General instructions
pfu basic range: Prefabricated concrete
enclosure, ground-level walk-in type
3. Couple the four hooks to the body's DEHA-type anchors,
as shown in Figure 6.6.
Figure 6.6. Correct coupling method using DEHA hooks
4. Lift and position the pfu body using the crane.
Figure 6.7. Lifting and positioning the pfu body
5. Once the body of the pfu is in place, uncouple the
hooks from the body's DEHA anchors.

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General instructions
pfu basic range: Prefabricated concrete
enclosure, ground-level walk-in type
Handling
6.2. Handling the roof
Where necessary, the pfu roof can be removed using the
threaded inserts set out on the top surface. Before handling the roof, disconnect the interior cable
that connects the pfu's roof and body.
6.2.1. pfu-3 and pfu-4 roofs
The weight of the pfu-3 and pfu-4 roofs is as follows:
Model Weight [kg]
pfu-3 Standard roof 2240
Raised roof 2630
pfu-4 Standard roof 2970
Raised roof 3415
Table 6.2. pfu-3 and pfu-4 roof weights
The following tools and equipment are required to correctly
handle the roof:
1Lifting beam
2Chains/slings (minimum length 3 m, maximum length 3.5 m)
3High-strength M20 rotating eyebolts
4Flat-head screwdriver
Figure 6.8. Tools and equipment required

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Handling General instructions
pfu basic range: Prefabricated concrete
enclosure, ground-level walk-in type
Proceed as follows to handle the roof:
1. Remove and set aside the four plugs that cover the
threaded inserts in the roof, using a at-head screw-
driver.
2. Thread the four rotating eyebolts in the inserts,
throughout their length.
3. Join the tools according to Figure 6.9.
135 T Lifting beam
2Chains/slings (minimum length 3 m, maximum length 3.5 m)
Figure 6.9. Lifting tools set
4. Hook the chain hooks on the eye bolts.
5. Lift the pfu roof using the crane.
When removing the roof, support it on wooden
boards. The boards can rest on horizontal ground or
the bed of a truck.
Figure 6.10. Lifting and positioning the pfu roof
6. Once handling is complete, release the four safety
hooks and unscrew the four rotating eyebolts. Return
the plugs removed in step 1.

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General instructions
pfu basic range: Prefabricated concrete
enclosure, ground-level walk-in type
Handling
6.2.2. pfu-5 roof
The weight of the pfu-5's roof is as follows:
Model Weight [kg]
pfu-5 Standard roof 4000
Raised roof 4600
Table 6.3. pfu-5 roof weight
The following tools and equipment are required to correctly
handle the roof:
135 T Lifting beam
2Chains/slings (minimum length 3 m, maximum length 3.5 m)
3High-strength M20 rotating eyebolts
4Flat-head screwdriver
Figure 6.11. Tools and equipment required
Proceed as follows to handle the roof:
1. Remove the six plugs that cover the threaded inserts in
the roof using a at-head screwdriver, and keep them
in a safe place.
2. Thread the six eyebolts in the inserts, throughout their
length.
3. Join the tools according to Figure 6.12. Hook the lifting
beam on the crane hook.
135 T Lifting beam
2Chains/slings (minimum length 3 m, maximum length 3.5 m)
Figure 6.12. Lifting tools set

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Handling General instructions
pfu basic range: Prefabricated concrete
enclosure, ground-level walk-in type
4. Hook the chain hooks on the eye bolts.
5. Lift the pfu roof using the crane.
When removing the roof, support it on wooden
boards. The boards can rest on horizontal ground or
the bed of a truck.
Figure 6.13. Lifting the roof with six threaded inserts
6. Once handling is complete, release the six hooks from
the bottom chains or slings, unscrew the six eyebolts
and return the plugs removed in step 1.
6.2.3. pfu-7 roof
The weight of the pfu-7's roof is 7750 kg.The following tools
and equipment are required to correctly handle the roof:
135 T Lifting beam
2Chains/slings (minimum length 3 m, maximum length 3.5 m)
3High-strength RD24 eyebolts
4Flat-head screwdriver
Figure 6.14. Tools and equipment required
Proceed as follows to handle the roof:
1. Remove and set aside the four plugs that cover the
threaded inserts in the roof, using a at-head screw-
driver.
2. Thread the four RD eyebolts in the inserts, throughout
their length.

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General instructions
pfu basic range: Prefabricated concrete
enclosure, ground-level walk-in type
Handling
3. Join the tools according to Figure 6.15. Hook the lifting
beam on the crane hook.
135 T Lifting beam
2Chains/slings
Figure 6.15. Lifting tools set
4. Hook the chain/sling hooks on the eye bolts.
5. Lift the pfu roof using the crane.
When removing the roof, support it on wooden
boards. The boards can rest on horizontal ground or
the bed of a truck.
Figure 6.16. Lifting and positioning the pfu-7 roof
6. Once handling is complete, release the four hooks from
the bottom chains or slings, unscrew the four eyebolts
and return the plugs removed in step 1.

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Transport General instructions
pfu basic range: Prefabricated concrete
enclosure, ground-level walk-in type
7. Transport
7.1. Road transport
Loading is carried out at Ormazabal's facilities using its
own equipment.
Using an articulated truck with platform height of less than
900 mm is recommended for transporting the pfu.
Transport should be planned well in advance,
envisaging all authorisations and any restrictions on
weight and length, in accordance with legislation in
the countries the building will travel through from the
factory through to its nal location.
Specic requirements for Spain:
Generic Authorisation for Special Transport of heights
up to 4500 mm and total weight of 45 t (weight +
load) must be obtained in advance. The weight of the
vehicle must not be more than 13 t when transporting
the pfu-7 (32t).

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General instructions
pfu basic range: Prefabricated concrete
enclosure, ground-level walk-in type
Installation
8. Installation
When installing the pfu at its location, it is essential to follow
current legislation on electrical installations in networks,
including both local regulations and the specications
of the utility company. The instructions included in this
document must be followed during electrical installation.
The site must be visited in advance to check if vehicles can
have access and if there is sucient space for the unloading
and assembly operations, taking into account the distances
to overhead lines, slopes, etc.
8.1. Receiving the equipment
Upon receipt of the building, carefully check the following:
1. The general condition of the assembly.
2. Absence of bangs or breakage, especially at the
connection points to other items or close to the DEHA
couplings.
3. The state of the paintwork, checking for the absence of
chipping, scratches, etc.
4. Accessories: If damage or absences are observed,
immediately inform the transport agent and Ormazabal.
8.2. Location
The site location should be precisely dened, indicating the
levels of alignment and height of the possible reference
points, such as: roads, kerbs, milestones, fences, pavilions,
pylons, etc.
Incorrect levelling may cause the base of the body to
break.

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Installation General instructions
pfu basic range: Prefabricated concrete
enclosure, ground-level walk-in type
8.3. Planning
On the location sketch or drawing, mark out the spaces
available for the crane and the transport truck.
DMaximum length of the crane elevation arm
Figure 8.1. Ooad operation
Model Distance "D" for handling the pfu
6000 mm 7000 mm 8000 mm 9000 mm
pfu-3 40 t. 40 t. 60 t. 60 t.
pfu-4 40 t. 60 t. 60 t. 80 t.
pfu-5 60 t. 60 t. 80 t. 100 t.
pfu-7 80 t. 100 t. 100 t. -
Table 8.1. Crane power in accordance with distance "D" for handling the pfu
For other distances "D", please contact Ormazabal.
The existence of any circumstance or object that could
impede or obstruct the smooth operation of the installation
must be indicated (posts, cables, ditches, walls, pipelines,
etc.), marking their positions on the drawing.
Pay special attention to the position the truck crane
to ensure the support jacks are not too close to the
excavation, which could lead to collapse. The support
jacks must be more than 2.50m from the excavation.