flexible urban networks lv author: i mcdonald€“-255...iec 60076-10:2005 power transformers, part...

Document Number: 255-018

Author: I McDonald

Revision No: 1

Date: 29/7/2015

Checked by: D Charlton

Sig: Embedded Systems Engineer

Authorised by: N Walker

Sig: Project Manager

2T-PED Installation Manual

Flexible Urban Networks – LV

Multi-Terminal Power Electronics

Device


System / Product: Flexible Urban Networks – LV / 2 Terminal Power Electronics Device


Document Revision: 1 of 26

UK POWER NETWORKS

TWO TERMINAL POWER ELECTRONICS DEVICE

PART NO. 800255

INSTALLATION MANUAL





The information enclosed in this document is to be considered proprietary information. It shall not be reproduced, disclosed or used without the prior written permission of Turbo Power Systems Ltd. © 2015

Turbo Power Systems Ltd

1 Queens Park,

Queensway North,

Team Valley Trading Estate,

Gateshead,

Tyne & Wear,

NE11 0QD

Tel. +44 (0) 191 4829200

Fax. +44 (0) 191 4829201

www.turbopowersystems.com

http://www.turbopowersystems.com/





1. AMENDMENT LIST

Revision No.

Date Comments Modified by

1 29th July 2015 First Issue I McDonald





2. TABLE OF CONTENTS

1. Amendment List ............................................................................................. 4

2. Table of Contents ........................................................................................... 5 3. Definitions, Acronyms and Abbreviations ....................................................... 6 4. Reference Documents .................................................................................... 8

TPS Documents ................................................................................................ 8

Customer Documents ........................................................................................ 8

Standards .......................................................................................................... 8

5. Health & Safety ............................................................................................ 10 The Safety Rules ............................................................................................. 10

Safety Precautions........................................................................................... 12

Precautionary Notices ...................................................................................... 12

6. Overview: ..................................................................................................... 13 7. Introduction................................................................................................... 14

8. PED Description ........................................................................................... 15 9. Delivery of Product to the Installation Location............................................. 17

10. Electrical Installation of The 2T-PED ........................................................ 20 11. Tools Required: ........................................................................................ 22 12. Safe Isolation procedure and fuse removal procedure ............................. 24





3. DEFINITIONS, ACRONYMS AND ABBREVIATIONS

Term Definition

ACCT Alternating Current Current Transformer

DCCT Direct Current Current Transformer

DG Distributed Generation

DNO Distribution Network Operator

DSR Distribution Safety Rules

EMC Electro Magnetic Compatibility

FEP Front End Processor

FUN-LV Flexible Urban Networks – Low Voltage

HMI Human Machine Interface

LCNF Low Carbon Network Fund

LV Low Voltage

MCCB Moulded Case Circuit Breaker

N/A Not Applicable

OC Open Circuit

PCB Printed Circuit Board

PED Power Electronics Device

PF Power Factor

PLC Programmable Logic Controller

PNDC Power Networks Demonstration Centre, Cumbernauld operated by Strathclyde University

PowerOn fusion UK Power Networks’ network management system supplied by GE Digital Energy.

PTE Portable Test Equipment

RMS Root Mean Square





Term Definition

RTU Remote Terminal Unit

SOP Soft Open Point

TBD To Be Decided

THD Total Harmonic Distortion

Tx Transformer

UKPN UK Power Networks (Operations) Ltd consists of three electricity distribution networks:

Eastern Power Networks plc (EPN).

London Power Network plc (LPN).

South Eastern Power Networks plc (SPN).





4. REFERENCE DOCUMENTS

TPS DOCUMENTS

Document Number

Title

255-010 Project Charter

Qf.75.1-255-018 System requirements Specification

CUSTOMER DOCUMENTS

Document Number

Title

EDS 08-0040 Engineering Design Standard – Dual-Terminal Power Electronics Device

PNDC/UKPN-001/TP-01B

Plan for Testing of “Soft Open Point” Power Electronic Device at PNDC

STANDARDS

Document Number

Title

EDS 02-0960 LV waveform mains cables

EDS 02-0033 LV waveform mains cables ratings

UK Power Networks

DSR

Distribution Safety Rules Summer 2012 Edition

BS EN 50178:1998 Electronic equipment for use in power

installations

BS EN 60529: 1992 Specification for degree of protection provided by enclosures (IP code)





Document Number

Title

BS EN 50300: 2004 Low-voltage switchgear and control gear assemblies. General requirements for low-voltage cable distribution boards

BS EN ISO 9001:

2000

Management and Quality Assurance Standards

BS EN ISO 14001: 1996

Environmental management systems – specification with guidance for use

ENA TS 48-5 Environmental test requirements for protection

and control equipment and systems

ENA ER G5/4-1 Planning levels for harmonic voltage distortion and the connection of non-linear equipment to transmission systems and distribution networks in the UK - October 2005

ENA TS 50-18 Application of Ancillary Electrical Equipment

IEC 60076-10:2005 Power Transformers, Part 10: Determination of

Sound Level

IEC 61000-2-12 Compatibility levels for low-frequency

conducted disturbances and signalling in public

medium-voltage power supply systems

IEC 61000-4-13 Harmonics and interharmonics including mains

signalling at a.c. power port, low frequency

immunity tests

HSE HSG224 The Construction (Design & Management)

Regulations 2007

HSE The Electricity at Work Regulations 1989

HSE The Health & Safety at Work Act 1974

HSE The Control of Substances Hazardous to

Health Regulations 2002

HSE PUWER 1998 Provision and use of work equipment

regulations

Ofgem Low Carbon Networks Fund Governance

Document v.6





5. HEALTH & SAFETY

WARNING

1. This test uses high voltage: “Due care” must be taken to maintain safety of the test personnel and any staff working near the test area if the unit requires to be powered up for test purposes.

2. This test uses high voltage: Follow Health and Safety Regulations and make full use of safety precautions. Working on live equipment is to be avoided if possible.

3. This test uses high voltage: No bell, buzzer or Megger tests to be carried out without circuit protection techniques being used.

4. This equipment contains static sensitive components: Anti-static precautions must be observed to ensure that equipment damage does not occur.

THE SAFETY RULES

1. De-energise. 2. Secure against switching on again. 3. Make sure that the equipment is dead. 4. NOTE follow warnings and instructions on safety label below. 5. Be aware PED has internal capacitors charged to 800V dc





DANGER

!PARALLEL CONVERTERS!

STORED ENERGY CIRCUIT

ISOLATE ALL SUPPLIES

AND ALLOW 5-MINS TO

DISCHARGE BEFORE

ATTEMPTING

MAINTENANCE

DANGER

HIGH VOLTAGE





SAFETY PRECAUTIONS

This chapter contains a list of general safety precautions. Before attempting any tasks, read and understand these precautions. Failure to do so can result in death/serious injury to individuals or damage to equipment. If in doubt regarding any of these precautions, ask for an explanation from your immediate supervisor before proceeding with any installation task.

PRECAUTIONARY NOTICES

WARNING:-

Indicates an operation, sequence, or function that, if not observed, may cause serious injury or death to personnel and/or serious damage to or loss of equipment. Strictly adhere to all warnings.

CAUTION:-

Indicates an operation, sequence, or function that, if not observed, may cause damage or malfunction of equipment.

NOTE:-

Provides additional explanatory information that may not be readily apparent from the text or illustrations.

Printed Circuit Boards (PCBs) and assemblies contain static sensitive components. Anti-static precautions such as rubber work mats on the bench and grounded wrist straps must be used when working on non-powered assemblies on the bench.





6. OVERVIEW:

This procedure gives instructions for the installation of UKPN 2T-PED product.

A single cabinet will be delivered on a wooden pallet and identified as indicated in Table 1

Table 1: Deliverables

Wooden Pallet 2T-PED Totals (Max)

Description

Part Number

Weight

Kgs

Dims

mm

Weight

Kgs

Dims

mm

Weight

Kgs

Dims

mm

2T-PED Enclosure

800255

32.5 1050(w) x1340(d) x150(h)

1020 800(w) x1200(d) x1550(h)

1052.5 1050(w) x1340(d) x1550(h)





7. INTRODUCTION

This document describes the procedure to safely install a 2T PED in its final location. The equipment is designed for pavement mounting, and is designed to be fixed to a pre-installed plinth.

Commissioning of equipment is described in separate commissioning document.

There are some basic requirements for siting the 2T-PED:

Space is required around PED on the pavement to allow access for maintenance

The rear of cabinet can be positioned close to a wall if required.

Read all of the instructions before beginning the installation process.

The Renley Cutouts must not be connected to the PED at any time during this installation process (see commissioning documents).

The delivery pallet must be kept upright and not be placed in the

horizontal position whilst transporting/manouvering.

Greate care must be taken when lifting and positioning the PED

enclosure in position. The equipment weight exceeds 1000kg.

After installation it is most important all covers are fixed in position

using the security fixings supplied, that all doors are closed and

securely locked.





8. PED DESCRIPTION

The 2T PED is a device used for sharing power between substations creating a Soft Open Point (SOP). It will also improve power quality addressing issues such as unbalance, power factor correction, and harmonic reduction. The PED is monitored and controlled remotely. The PED incorporates a Local/Remote switch just behind the control enclosure door, which is normally set in the ‘Remote’ position. When the switch is in the ‘Local’ position the PED is controlled locally by connecting an HMI module (intended for carrying out commissioning or maintenance).

The power from the substations comes into the PED into the bottom of the magnetics enclosure. It is important that the phase relationship is maintained between substation (A), L1, L2, L3 and substation (B), L1, L2, L3 in order for the equipment to work correctly.

The Protective Earth (PE) / Neutral (N) connection bus bar (PE/N) within the PED must be bonded to the incoming cable sheaths and to the locally installed embedded ground mat. Prevention of electric shock to pedestrians is determined by the quality of the grounding of this equipment. To maintain safety the bond resistance should be <500 micro Ohms (with a prospective short circuit current of 46KArms, a person in contact with the equipment with be subjected to a voltage <23Vrms which is considered safe for the majority of people).

The remote control room and monitoring is controlled by DNP3 communication system via a 3G modem. Measurements from the substations are also communicated via the 3G link so that the PED can control the power flows correctly. If communications stops working then the controller within the PED will decide on action to take (such as reduced functions or disconnection of the equipment). The PED may start and stop at any time when in ‘Remote’ mode, depending on external conditions.

The PED is cooled using internal cooling fans that force airflow to remove the heat losses within the equipment. The target loss for the 2T-PED is <12kW. The majority of the heat loss comes from the seven filter inductors in the base and the inverter heatsinks in the centre. Three fans are used to cool these components, located in the roof. An additional single fan/filter unit is mounted to the control enclosure door for cooling the control equipment.

There is a thermal de-rating mechanism implemented within the PED to reduce power flow in extreme ambient temperature or reduced ventilation conditions. If the equipment temperature exceeds its design maximum the equipment will shut down and will only restart when the temperature fall below a reset level.

The various analogue and digital status values are recorded internally using an embedded diagnostic and monitoring system. Both live and historic data can be retrieved using TPS’s proprietary Portable Test Equipment (PTE) software, running off any standard PC connected to a serial connector on the internal front door located in the control cabinet.





Some limited control and monitoring is also available using an HMI - a touchscreen control unit, used when first commissioning a PED or when completing maintenance operations. The HMI is connected via a socket on the internal front door located in the control cabinet, and a mains power socket is also provided in order to power the HMI. Limited control is available to test out the PED before putting into service by switching the equipment into ‘Local’ mode.

The panel found in the control enclosure has the following functions present:

Ethernet connection for external HMI and reprogramming (may be required for commissioning or maintenance)

PTE connector (to access the internal fault monitoring system)

Auxiliary power isolation switches SW1 and SW2

230VAC utility socket for powering external equipment (rated at 6 Arms)

Local/Remote switch SW3

SW1 SW2 SW3

Ethernet PTE





9. DELIVERY OF PRODUCT TO THE INSTALLATION LOCATION

Centre of Gravity

Delivery will require an open backed wagon in conjunction with a mobile crane or Hi-Ab. The PED should only be lifted with shackles and lifting straps suitable for lifting >1020kg. The PED lifting points are positioned on the right and left hand side at the bottom corners of the magnetics enclosure.

Figure-1 PED Lifting Eye

Figure-1 PED Lifting Eyes

3D-Model Front View

Lifting points

present on both sides of the enclosure





The PED should then be lifted from the wagon and lowered into position onto the pre-installed plinth with cables positioned correctly to fit through the holes in the base of the 2T-PED enclosure.

The enclosure fixing points are located in each corner of the control and magnetics enclosures. The fixing points are 14mm clear holes intended for M12 bolts.

If any unevenness is found present between the PED and the plinth during installation it may require a gasket be fitted.

Recommended mechanical torque

M12 hold down bolts - 40Nm (mild steel)

After mounting the PED the lifting eye bolts should be removed and replaced with the stainless steel bolts supplied. The eye bolts placed inside the PED for safe keeping.

NOTE: The PED unit is delivered with input MCCBs locked in their OPEN position. The input Renley Cutouts are supplied without fuses fitted.

UKPN will supply the correct fuse to be fitted to the Renley Cutouts.

Figure-2 Renley 350Arms Cut Out

Although the PED is supplied with input MCCBs in the open position TPS would





prefer if the Renley Cutout fuses were not installed during the installation phase. The fuses should to be left loose in the magnetics enclosure for insertion during the commissioning phase.

A set of 2 keys is supplied with each PED. These are attached to the outside of the control enclosure door, and should be removed and securely stored.





10. ELECTRICAL INSTALLATION OF THE 2T-PED

Once the cabinet is in position and mechanically fixed down the substation supply cables are to be connected.

The PED cable terminations points are:

PE/N left and right bus bars located on each side of the magnetics enclosure

Renley Cutouts suitable for termination of 185mm² solid aluminium cable (as specified by UKPN)

2T-PED Terminations

Description Conductor CSA (mm²)

Crimp Comment

1 Substation (A) phase cables

185 Not required for Renley Cutouts

3 x solid aluminium conductors

2 Substation (A) PE/N cable sheath

Unknown Bus bar M10 clear hole

Sheath conductor terminated with crimp

3 Substation (B) cable 185 Not required for Renley Cutouts

3 x solid aluminium conductors

4 Substation (B) PE/N cable sheath

Unknown Bus bar M10 clear hole

Sheath conductor terminated with crimp

5 Ground mat Unknown Bus bar M10 clear hole

Conductor format unknown

Electrical connection torque

M10 Crimp - 40Nm (high tensile grade 8.8 fixings)

M6 Renley Cutouts - 4Nm





Figure-3 PED Substation Cable Entry View

185mm²

Substation

Cable





11. TOOLS REQUIRED:

Lifting shackles and straps

Lifting equipment - miscellaneous

Spanners, sockets, screwdrivers, cutters

Stanley knife

Torque wrench – up to 40Nm

Security fixing bit-set

Cabinet key





Installation Check List 2T-PED Serial Number: _____________

Requirement Satisfactory (Y / N / NA)

Installation team

Sign & date

800-255 2T-PED Enclosure

Before installation complete visual check for any damage that may have occurred during transport

Ensure that a safe lifting procedure is followed while positioning the equipment

Check that fixing down bolts are fitted and torqued correctly

Substation (A) Cable;

Check that Renley Cutout 185mm² cable clamp bolts are tightened to the correct torque value

Check that PE/N conductor is crimped correctly and bolted to bus bar to the correct torque value

Substation (B) Cable;

Check that Renley Cutout 185mm² cable clamp bolts are tightened to the correct torque value

Check that PE/N conductor is crimped correctly and bolted to bus bar to the correct torque value

Ensure that substation (A) and (B) cable cleats are fitted and tightened correctly

Warning: Do not install fuses into Renley Cutouts.

(fuses to be fitted during commissioning phase)

Replace magnetic compartment covers, ensuring that grounding straps are fitted and tightened up to the correct torque value

Check that magnetic compartment covers security fixings are all present and tightened to their correct torque value

Close and lock any doors that were opened during installation





12. SAFE ISOLATION PROCEDURE AND FUSE REMOVAL PROCEDURE

Open the control enclosure door. Turn the Local/Remote switch SW3 to ‘Local’ (clockwise) and wait until both MCCBs have opened.

MCCBs may already be open if the PED was not running. They may open immediately when switched to ‘local’ or they may take up to 2 minutes depending at the power rating that the PED is operating at. MCCBs status can be checked by visually inspecting the ON/OFF flags on the front of the MCCBs (see the illustrations below).

MCCB open (‘0 OFF’ displayed) MCCB closed (‘1 ON’ displayed)





Once the system has shut down, open switches SW1 and SW2 and secure with padlocks

If MCCBs have not opened after 2 minutes, lock off SW1 and SW2 as shown above then manually open the MCCBs:

To manually open an MCCB, set the MCCB to ‘manual’ and press the ‘OFF’ button.





Once both MCCBs are open (automatically or manually), switch them to the locked position and secure the hasp with a padlock.

Observe the discharge period for the DC link.

The PED can now considered to be dead and the Renley Cutout fuses may be removed. This operation is outside the scope of this document.

When the Renley Cutout fuse is removed, the incoming terminal inside the Renley Cutout will still be energised. Appropriate care should be taken, including fitting a safety cover where necessary.