283-ap5-omm-0105-0007 operating and maintenance manual … … · title: rectifier control...

283-AP5-OMM-0105-0007Operating and Maintenance Manual for Cathodic

Protection – APS5Revision : 00

Confidential and proprietary

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00 2010-11-09 First Release




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OPERATING AND MAINTENANCE MANUAL FOR THE CATHODIC PROTECTION-APS 5

TABLE OF CONTENTS

1 APPENDIX A: OPERATING AND MAINTENANCE MANUAL FOR THE CATHODIC PROTECTION T.R.U 5 2 APPENDIX B: TECHNICAL MANUAL FOR THE CATHODIC PROTECTION GAUTRAIN-APS 5 RHODESFIELD 6




of 6

1 APPENDIX A: OPERATING AND MAINTENANCE MANUAL FOR THE CATHODIC PROTECTION T.R.U

(16 Pages)

Title: Rectifier Control Operation and Maintenance Manual Date: 06 June 2010 Manual Number: CPA100382

OPERATING AND MAINTENANCE

MANUAL FOR THE

CATHODIC PROTECTION T.R.U

PROCUREMENT: DISA CATHODIC LOCATION / SITE: GAUTRAIN PROJECT DESCRIPTION: CATHODIC PROTECTION RECTIFIERS RATING: 0-20 Volts DC@10 & 20 amps SUPPLIER SERIAL # CPA 100382

GALVA ELECTRONICS CC. (Reg. 1994 / 039817 / 23) t / a

Address: 16 STAAL STREET, KYA SAND, RANDBURG, SOUTH ARICA. P.O. BOX 1014, CRESTA, 2118

Phone: +27 11 462 4253 Fax: +27 11 462 4310 Web: www.switches.co.za

E-mail: [email protected]


CONTENTS

SECTION DESCRIPTION PAGE

1. SUPPLIER INFORMATION 3

2. VENDOR DOCUMENTS 4

3. COMPONENT LIST 8

4. COMMISSIONING AND OPERATING & MAINTENANCE MANUAL 10

8.1. PRE-COMMISSIONING/COMMISSIONING PROCEDURES

8.2. DATA BOOK

5. SPARE PARTS SCHEDULE 19

6. DRAWINGS 20

10.1. ELECTRICAL 10.2. MECHANICAL


SECTION 1: SUPPLIER INFORMATION

GALVA ELECTRONICS CC. (Reg. 1994 / 039817 / 23) t / a

Address: 16 STAAL STREET, KYA SAND, RANDBURG, SOUTH ARICA. P.O. BOX 2051, NORTHRIDING, 2162

Phone: +27 11 462 4253 Fax: +27 11 462 4310 Web: www.rectifier.co.za E-mail: [email protected] Contact Person: Johann van der Westhuyzen


SECTION 2: VENDOR DOCUMENT ELECTRICAL SPECIFICATIONS Output: 20V DC, 10 & 20 A DC Output Input: 220VAC, 1 phases, 10 OR 12 Amps. Output Control: Thyristors controlled MECHANICAL SPECIFICATIONS Panel Material: 3CR12 Steel Panel. Mounting: Floor standing Dimensions: 1300mm (BT) x 1600mm (LR) x 700 mm (BF) GENERAL DESCRIPTION The Transformer Rectifier Unit is a device which supplies direct current (DC) which is used to provide cathodic protection. Without it, cathodic protection is lost and corrosion can occur. The Transformer Rectifier Unit (TRU) receives 220V single phase AC mains power and by means of a step down transformer, Rectifier Bridge and smoothing chokes, which converts it to low voltage DC. A fuller description is given below. 2.1 AC and DC Current Flow

The 220V input supply is fed into the unit from a circuit breaker external to the unit. Current enters the unit via a circuit breaker and is controlled by thyristors into a double wound, transformer. From the secondary of the Transformer the AC is fed into a single phase full wave silicon diode rectifier bridge where it is converted to DC. From the bridge the DC flows through two fuses and two chokes located on the positive and negative legs and on to the busbars.

2.2 Meters The TRU contains the following meters.

1. An analogue meter to measure the DC voltage at the output terminals.

Rating 0 - 20V 2. An analogue meter to measure the DC current flowing out of the TRU.

Rating 0 – 10 & 20A 3. A digital meter to indicate the values measured at the individual; reference

electrodes.


2.3 Transient Protection

The T.R.U. is connected directly to the protected rail and is therefore particularly exposed to transients. It therefore incorporates a number of characteristics and devices for protection against voltage and current transients. The greatest risk is from voltage transients entering the T.R.U. from the load. The voltage and current ratings of fuses, semiconductors and surge diversion units are closely matched for optimum protection. In the event of any component failure, it must be replaced with exactly the same rating. This is particularly important for the PIV rating of semiconductors. 2.3.1. Current Transients: Protection against AC transients is provided by the

circuit breaker. Three fuses, between the transformer secondary and the rectifier

bridge, also provide further protection against AC transients. The fuses are rated at 10 or 20 Amps

Protection against DC transients is provided by two fuses located on

the positive and negative DC legs. The fuses are also rated at 10 or 20A.

2.3.2. Voltage Transients The thyristors and diodes are each protected by means of a RC

snubber circuit.

An elaborate surge protection network is provided between the diode bridge and the load terminals. The design of this network is integral with the overall surge protection and earthing of the structure.

Working from the load towards the bridge, the following components

are installed: • A MOV (Over voltage arrestor) between positive and negative, positive

and earth, as well as negative and earth. • Another higher voltage rated MOV (Over voltage arrestor) is placed

between positive and negative. • A current lightning arrestors is placed between positive and negative. • Two 1 mH choke in both positive and negative legs.

• A 220V blitzductor is situated after the step down transformer feeding the power to the meters and transducers.


2.4 “CONSTANT VOLTAGE”, “CONSTANT CURRENT” & “CONSTANT STRUCTURE” REFERENCE CONTROL OPTIONS.

The Rectifier output is controlled by the firing angle of the Thyristors in the primary circuit. The control characteristic is either constant output voltage, constant output current or from the rail reference electrode potential feedback. The desired output is adjusted by means of a control potentiometer.

2.4.1 CONSTANT VOLTAGE The unit will maintain a constant output voltage up to the maximum output voltage. Select Control (V) at the control selector switch; then adjust the potentiometer to the desired voltage rating. The rectifier will maintain a constant voltage and the current will change according to the resistive load.

2.4.2 CONSTANT CURRENT

The unit will maintain a constant output current up to the maximum output current. Select Control (I) at the control selector switch then adjust the potentiometer to the desired amperage rating. The rectifier will maintain a constant current and the voltage will change according to the resistive load.


2.4.3 STRUCTURE REFERENCE

The unit will maintain a constant reference electrode target setpoint value by controlling the output voltage of the rectifier. Select “Const. Structure” at the control selector switch then adjust the potentiometer to the desired setpoint.

NB! WHEN SELECTING BETWEEN CONTROL (V), CONTROL (I) OR

CONSTANT STRUCTURE, PLEASE ENSURE THAT THE ADJUST POTENTIOMETER HAS BEEN TURNED DOWN (ANTI-CLOCK WISE)

BEFORE CHANGE OVER.

A CHANGEOVER SHOULD ONLY OCCUR, ONCE THE VOLTAGE & CURRENT HAS DIMINISHED TO ZERO VOLTS AND AMPS.


SECTION 3.1: COMPONENT LIST- PAGE 1/2

ITEM AS PER

DRAWING DESCRIPTION MANUFACTURER

SUPPLIER TYPE RATING

1. Circuit breaker HAGER ND110 220V.A.C, 10 OR 12A, 1 Pole

2. Fuse Holder Bussman CH101E 10x38mm

600V; 32Amps

3. Contactor Lovato BF9.10 220VAC Coil

4. Current Transformers

5. Thyristor stack CONTROL TECHNOLOGY PH1 15Amps, 22VAC

6. RC-Networks Current Automation 50010 800~1000VAC

Capacitor, 22 Ohm 10 Watt Resistor

7.

8. Main Transformer RT Isolated at 16KV – Primary to Secondary

9. Resistors CGS HSA50 1K, 50 Watt

10. Fuse Holder Bussman 170H1007 250A

11. AC Fuses Bussman 50A

12. Diode Stack Westcode

95PF 95PFR 50A

14. Three phase diode bridge International Rectifier 36MT160 36Amps

15. Ammeter HEW 10 OR 20Amp. 50mV 96x96mm

16. DC Fuses Bussman 170M2668 25A

17. Over voltage arrestors Dehnguard 275VAC CAT NO. 900 600

18. Choke Isolated at 12KV – Primary to EARTH 1mH , 10 OR 20A

19. Shunt DMS Power 10 OR 20Amp, 50mV

20. Terminal Post AK GPE120 16A, 16mm

21. Voltmeter HEW 20VDC 96x96mm

22. SEE ITEM 5

25. Synchronising Transformer


SECTION 3.2: COMPONENT LIST- PAGE 2/2

ITEM AS PER

DRAWING DESCRIPTION MANUFACTURER

SUPPLIER TYPE RATING

29. Earth leakage unit Hager AD866 16Amp

30. Plug point Crabtree Single socket 16A

32. Light Crabtree 100Watt

33. Circuit breaker Hager Nd106 6A, single phase

34. Selector switch AUSPICIOUS CA10A250-603E

35. Relay & socket FINDER 220VAC COIL 2 changeover

36. Timer Electro R2U

37. Potentiometer PIHER CP-21 5K Ohm (10 Turn pot)

38. Temperature sensors KSD250V 80oC; 220VAC, 5Amps

39. PID Controller

40. Transducer 9000 -5-0+5VDC / 0-5VDC

41. Selector switch AUSPICIOUS CA10A250-603E

42. Digital Voltmeter DITEL JR-VDC 10-0-10 VDC

46.

47.

48. Surge Arrestor Blitzductor KT Type: VED Cat no: 919 642/643

Pilot Light Lovato LM2TIL104 250V


SECTION 4.1: COMMISSIONING AND OPERATING AND MAINTENANCE MANUAL.

4.1.1 PRE-COMMISSIONING PROCEDURES.

Please check the following important criteria, before switching on.

- Circuit breaker / Fused Isolator

Check for loose connections at distribution board feeding the rectifier, as well as at the rectifier. Tug on each wire to ensure that the supply cable does not slip out of the circuit breaker. Failure to ensure a tight connection on both sides will result in internal component failure, as a result of arcing.

- Earthing

Check for adequate Earthing to the unit. Please remember that an earth connection should never be used through a metal frame, but only via a correctly sized wire to the rectifier. Failure to ensure an adequate earth will result in a floating system and internal component failure will result.

- Bus bar

Check for a tight and clean connection, at the output buss bars. If the buss bar connections are dirty or loosely connected a heat problem will be generated.


OPERATING INSTRUCTIONS 4.1.2 Start up Procedure (MANUAL CONTROL)

i.) Before switching the TRU on ,ensure that all connections are tight and all the components are in place and that the 220V supply is “healthy”

ii.) Turn the adjust potentiometer totally anti-clockwise

iii.) Close the circuit breaker to supply power to the TRU

iv.) Ensure that the following criteria are all in a healthy condition (i.e. the light is

burning on the control panel a) AC Fuses healthy b) DC Fuses healthy c) POWER ON

v.) Select the mode of operation to either constant current “Control (I)” or constant

voltage “Control (V)” or “Constant Structure”

vi.) Adjust the control potentiometer to obtain the required D.C output. Observe the output voltage and current. The unit incorporates current limit protection against short circuits. Ensure that the DC current does not exceed 30A or 70A.

NB! If it does, the control card settings require adjustment and should be referred to the manufacturer. (However this should be a last resort and not the first option.)

vii.) After switching on, monitor the unit for about one hour to ensure that there are

no hot spots and everything is functioning smoothly. If everything is in order, set the voltage to progressively higher values, and if possible up to the maximum provided the maximum current rating of the unit is not exceeded.


4.1.3 ROUTINE MAINTENANCE It is recommended that the Rectifier be visited at least once a month. This is not only in order to carry out preventative maintenance but also to ensure that it is in fact functioning and re-energize it if it is not. During the monthly visits the following should be carried out. - Enter value of meter outputs into a log book. - Repair or replace failed components. - Check for loose connections. - Blow out dust.


SECTION 4.2: DATA BOOK Issue No. Description Revision

No. Revision

Date Signature


SECTION 5: SPARE PARTS

ITEM AS PER

DRAWING DESCRIPTION RECOMMENDED

QUANTITY


SECTION 6: DRAWINGS 6.1 ELECTRICAL: 6.2 MECHANICAL:


7. ACCEPTANCE CERTIFICATES

This is to place on record that the undersigned has examined and witnessed the Transformer Rectifier Unit and furthermore that the unit fully comply with specifications requested. The units may now be handed over to the clients. Approved Exemptions: Name: Signature: for and on behalf of the client:




Page 6 of 6

2 APPENDIX B: TECHNICAL MANUAL FOR THE CATHODIC PROTECTION GAUTRAIN-APS 5 RHODESFIELD

(43 Pages)

283-ap5-omm-0105-0007 operating and maintenance manual … … · title: rectifier control...

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