Project Title:

AQABA OIL TERMINAL PROJECT

Document Number: WMC-MAN-AOT-EL-010 Revision Code: 1 Page: 1 of 51

Document Title: Operating Instruction of 33kV and 3kV switchgear and motor
Contract No: 1/W/2012
control center

Employer: Consultant: EPCC Contractor:

OPERATING INSTRUCTION OF 33KV AND 3KV SWITCHGEAR AND

MOTOR CONTROL CENTER

2016.6.29

1 29.06.2016 For Information Liu Xue Renyanang Li Ruihe

0 18.01.2016 For Information Liu Xue Renyanang Li Ruihe

Rev. Date Issue Purpose / Description Prepared Checked Approved

Project Title:
AQABA OIL TERMINAL PROJECT

Document Number: WMC-MAN-AOT-EL-010 Revision Code: 1 Page: 2 of 51

Document Title: Operating Instruction of 33kV and 3kV switchgear and motor
Contract No: 1/W/2012
control center

INDEX

1 OPERATION&MAINTENANCE MANUAL(UNIGEAR ZS1) 3

2 OPERATION&MAINTENANCE MANUAL(UNIGEAR ZS3.2) 30

3 OPERATION&MAINTENANCE MANUAL(MMECB) 42

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 ABB Technology Ltd
Dept.: PPHV TC Doc. 10: <2GHVOI9795> Date: 2014-03-19
Prep. by: <Lucy Cheng> Lang.: EN Page 10 of20
Reviewed by: <Richard Zhang> Doc. Type: Manual Rev.: 1.0
App. by: <Howard Li> Sensitivity: <Internal> Document Status: Draft
MMECB User Manual
Q
Inom=,;,,3"xv
Where Q = PFC System Var's
V = System Voltage
Ensure correct phasing of cables from the main switchboard to the incoming connections of the PFC
System.
CONTACT YOUR LOCAL SUPPL Y AUTHORITY FOR FURTHER INFORMA TlON ON THE
CHOICE OF INSTALLATION CABLE FOR THE POWER FACTOR CORRECTION
EQUIPMENT.
4.2.2 Field Control Wiring
4.0nun2 control cable is generally suitable for Current Transformer secondary circuits.
However, over shorter/longer distances ABB advises that control wiring size is selected based on the
cable run, secondary current and the VA rating of the transformer. Typically multi-core cable is
recommended.
2.5mm2 control cable is usually suitable for the Voltage Transformer secondary and auxiliary supply
circuits. However, over shorter/longer distances ABB advises that the control wiring size is selected
based on the voltage drop. Typically multi-core cable is recommended.
Control connections between each power module (where applicable) have to be connected to the
control terminals. The terminals in stages are to be connected into the control cubicle.
5 Operation Instructions
5.1 Pre-Commissioning MMECB
Before energizing the bank, ensure the assembly is according to the General Anangement
Drawing, in particular check that the capacitors have been correctly installed and the appropriately
sized fuses have been fitted. Furthermore, it is particularly important to ensure that all mechanical
and electrical connections have been correctly tensioned.
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Prep. by: <Lucy Cheng> Lang.: EN Page II of20
Reviewed by: <Richard Zhang> Doc. Type: Manual Rev.: \.0
App. by: <Howard Li> Sensitivity: <Internal> Document Status: Draft
MMECB User Manual
• Ambient Temperature:
The capacitor bank must not be operated in an ambient temperature outside the stated temperature
class.
• Unbalance current (where fitted):
The unbalance current should not exceed 10% of the tripping value of the protection system.
5.1.2 Insulation Resistance Testing
Perform an insulation resistance test between all live conductors and earth to ensure the integrity of
the insulation.
5.1.3 Earth Resistance Measurement
Ensure the earth connections of the earthing system are such that the earth resistance does not
exceed acceptable levels.
5.1.4 Special Precautions
The voltage and current margins stated above are intended to allow operation during temporary
peaks. These margins should not be used under normal service conditions. Voltages and currents
should therefore be measured under all the load situations that occur, in order to ensure that the
capacitor bank is not overloaded.
Pay special attention to periods oflow load. A capacitor bank always causes a small increase in
voltage. At low loads this can result in problems, since the voltage may already be high even
without the capacitor bank.
When the load is low there is also a risk of resonance between the capacitors and transformers, and
this may give rise to considerable over voltages.
5.2 Pre-Commissioning Control Cubicle
With the equipment isolated from the supply, check the tension of all connections, earth bonding
and ensure enclosure is free of all debris.
5.3 Commissioning
Turn on the miniature circuit breakers in the MMECB control cubicle. Perform the commissioning
under normal operating conditions. Ensure that the relevant information has been entered into the
power factor controller. (If fitted)
5.4 Trouble Shooting
B: The trouble shooting hints provided here may not (depending upon
selected options) apply to your particular MMECB unit
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Prep. by: <Lucy Cheng> Lang.: EN Page 12 of20
Reviewed by: <Richard Zhang> Doc. Type: Manual Rev.: 1.0
App. by: <Howard Li> Sensitivity: <Internal> Document Status: Draft
MMECB User Manual
A) If the stage contactors in the capacitor banks do not switch in, in manual or auto mode.
Check that the control wires are correctly connected to the power modules. Check that the
contactors are energized. Ensure that the reset and switch on delay times (set on the controller) have
expired.
B) If all capacitors are switched on, and the required reactive power is relatively low.
Check that the CT has been placed on the line side of the capacitor.
C) There is no power to the RVT/RVC Controllers.
Turn on the Miniature Circuit Breakers in the control cubicle.
D) The RVT/RVC power factor controller will not operate even though it is on.
Check the programmed parameters of the RVT/RVC (eg. target power factor, alarms, etc.)
E) The controller is connected but does not work (nothing on the screen).
Check the voltage setting and the fuse located on the back side of the controller.
F) The preset power factor is not achieved.
At low or no load, a low power factor can correspond to a very small inductive current. The
con'esponding capacitor steps are too large for compensation. If the average cos <I>over a period of
time is too low, the preset cos <p may be increased.
G) The alarm function is activated although everything seems normal.
A very high demand of reactive power during a few minutes may make the bank insufficient to
compensate the required amount of reactive power. It will therefore indicate an alarm
5.5 Power On
After completion of the above checks, remove the HV Circuit Breaker (where fitted) from the test
mode and place in the run mode.
Check the power factor improves as capacitor stages are switched on.
5.6 Indication lights
Depending upon the options selected and model type, your MMECB unit may be fitted with a
number of indication LED lights. Table 5. I below describes any actions which may need to be taken
if these lights are illuminated.
Table 5.1 - Actions required
LED Label Colour LED on indicates
Power factor Yellow The minimum power
Not reached factor cannot be reached
with all steps energized.
Stage On Red Capacitor stage is No action required.
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~m~~~MM=n.
We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to
third parties without express authority is strictly forbidden.
2016.6.29
Dept.: PPHV TC Doc. 10: <2GHVOI9795> Date: 2014-03-19
Prep. by: <Lucy Cheng> Lang.: EN Page 130[20
Reviewed by: <Richard Zhang> Doc. Type: Manual Rev.: 1.0
App. by: <Howard Li> Sensitivity: <Internal> Document Status: Draft
MMECB User Manual
energized. Warning light only.
Stage OFF Green Capacitor stage is not No action required.
energized. Warning light only.
Over Temp Yellow An over-temperature trip Investigate cause of over-temperature.
has occurred in the stage. Reset latching trip relay in control
cubicle.
Over Pressure Yellow An over-pressure trip has Check for faulty capacitor units.
occurred in the stage. Replace capacitor unit if required.
Unbalance Trip Yellow The relay is detecting Check for faulty capacitor units.
unbalance current for the Replace capacitor unit if required.
stage Reset unbalance relay
Fuse Blown Yellow A HV fuse has blown in Investigate cause of blown fuse.
the stage. Replace HV fuses.
6. Maintenance
The MMECB System is designed with robust equipment and is intended for long-term usage.
However, maintenance is imperative to ensure a long life span.
Correct tension of all joints/connections is an important maintenance issue.
Incorrectly tensioned joints/connections will result in high resistive joints being formed, causing an
unstable operational environment for the equipment.
We recommend the following maintenance program, which will guarantee a long operational life for
the MMECB.
SAFETY
ffi FOR UNITS DESIGNED TO GBIT11024 and IEC60871 - ISOLATE & EARTH
SUPPL Y. WAIT TEN MINUTES. APPL Y HAND EARTHS TO ALL CAPACITOR
TERMINALS.
illA discharging device is not a substitute for short-circuiting the capacitor
terminals together and to ground before handing.
6.1 General Maintenance
An annual inspection is generally sufficient, unless the capacitor bank is exposed to
conditions of any kind, such as excessive contamination.
At each inspection, proceed as follows:
2016.6.29
 ABB Technology Ltd
Dept.: PPHV TC Doc. ID: <2GHVOI9795> Date: 2014-03-19
Prep. by: <Lucy Cheng> Lang.: EN Page 14 of20
Reviewed by: <Richard Zhang> Doc. Type: Manual Rev.: 1.0
App. by: <Howard Li> Sensitivity: <Internal> Document Status: Draft
MMECS User Manual
• Check capacitor unit capacitance.
• Check tension of all electrical joints/connections.
• Check operation of the ventilation equipment.
• Check operation of the anti-condensation heater.
• Remove all dust deposits and clean all equipment.
• Clean filters and replace if necessary.
(Refer to section 6.4 on filter removal)
6.2 Capacitance Measurement
Using ASS's capacitance bridge type CS IO. the capacitor unit measurements can be performed
without making any disconnections within the bank. Alternatively a digital capacitance meter may
be used following unit disconnection.
If the measmed value deviates with more than 101% from the value given in the test report (or shown
on name plates) the capacitor unit should be replaced.
6.3 Faulty Capacitor Units
SAFETY
ill CAPACITOR UNITS CAN HAVE A LETHAL CHARGE FOR LONG PERIODS (FEW
WEEKS) EVEN IF THE TWO EXTERNAL CONNECTIONS ARE SHORTED BY A
CONNECTING WIRE.
ill NO ASSUMPTIONS SHOULD BE MADE WHEN DEALING WITH A DEFECTIVE
UNIT. TREAT ALL UNIT CONNECTIONS AS PO TEN TlALL Y LIVE.
ill ENSURE CAPACITOR IS "SHORTED" OUT AS PER FIGURE 6.1 BELOW USING
2.5MM BUILDING WIRE, OR 30 AMP FUSE WIRE.
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Dept.: PPHV TC Doc. 10: <2GHVO 19795> Date: 2014-03-19
Prep. by: <Lucy Cheng> Lang.: EN Page 15 of20
Reviewed by: <Richard Zhang> Doc. Type: Manual Rev.: 1.0
App. by: <Howard Li> Sensitivity: <Internal> Document Status: Draft
MMECB User Manual
Shorting wire
7~
Figure 6.1 Shorting of faulty Units.
Leaking capacitors should be replaced. Spilt impregnation fluid can be absorbed with sawdust. Use
a rag moistened with a solvent, such as methylated spirits to clean hand tools.
Rags, sawdust, etc. soaked with FARADOL may be burned.
For disposal of faulty units, first the fluid should be drained by either puncturing the case or
removing the filler plug. The fluid is normally incinerated and the drained unit disposed of in a
controlled land- fill.
ftf Any disposal must be in accordance with local environmental regulations.
6.4 Filter Removal
• To remove the filter panels unscrew the six M6 screws on the fan hood.
• Remove the fan hood.
• Remove the filter panels for inspection and cleaning or replacement as required.
6.5 Spare Parts
For replacement parts please contact ABE. Refer to the Product Information for equipment lists
containing description of major parts and ABB part numbers
7 Technical Specifications
General
System Voltage 1-IOkV
Control Voltage AC 220V Standard #
Output 8Mvar #1
Frequency 50Hz
Location indoor
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Dept.: PPHV TC Doc. tD: <2GHVOI9795> Date: 2014-03-19
Prep. by: <Lucy Cheng> Lang.: EN Page 16 of20
Reviewed by: <Richard Zhang> Doc. Type: Manual Rev.: 1.0
App. by: <Howard Li> Sensitivity: <Internal> Document Status: Draft
MMECB User Manual
Ambient Temperature -250C/+450C #2
Altitude ::;1000 m
Humidity Maximum 95% day, 90% month
Insulation Level 10kV: 42175kV ElL
6kV: 30/60kV ElL
Short Circuit Current Maximum 31.5kA for 2s
Bank Configuration Fixed, switched single or multi step
Standards DL1T604, GB50227, GBII024
Capacitors
Phase Single
Fusing Internal or unfused
Discharge Resistor Built-in
Losses ::;0.2W/kvar including resistors
Dielectric Polypropylene film
Impregnant Faradol, non PCB
Container Stainless steel
Bushings High strength porcelain
Detuning Reactors
Type Three phase, iron core
Inductance Specific to application
Continuous current Specific to application
Harmonic loading Specific to application
Limit of linearity (95%) ? 1.8 x nominal current
Temperature class F
Vacuum Contactors
ABB VSC Electrically latched
Voltage 7.2kV, 12kV
Phase Three
Continuous current rating 230A capacitive
Mechanical endurance 100,000+ CO
Auxiliary contacts Available
Mechanism Magnetic actuator
Isolator with Earth Switching
ABB NAL
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Prep. by: <Lucy Cheng> Lang.: EN Page 17 of20
Reviewed by: <Richard Zhang> Doc. Type: Manual Rev.: 1.0
App. by: <Howard Li> Sensitivity: <Internal> Document Status: Draft
MMECB User Manual
Type Air insulated
Phase Three
Current rating 630A
Short time current 31.5kA for 2s
Auxiliary contacts Available
Mechanism Snap action spring (hand operated)
Interlocking Available
Surge Arresters
ABB YH5WR
Nom. Discharge current 5kA
Square wave discharge current capacity 600A for 2ms
Material Silicon rubber
Cooling Fan
Type Centrifugal
Volume 3160 m3/h
Noise level 66 dB[A]
Power 245W
Anti-condensation Heater
Rated voltage nOVAC
Heat output 300W
Busbar
Type Hard drawn copper
Surface finish Tinned
Discharge Coil
Type Dry
Phase Singe
Rated primary voltage Specific to application
Rated secondary voltage 100N3 Vor 100/3V or 100V
Discharge performance
Current Transformer
ABB. LZZBJ9
Type Dry
2016.6.29
 ABB Technology Ltd
Dept.: PPHV TC Doc. ID: <2GHVOI9795> Date: 2014-03-19
Prep. by: <Lucy Cheng> Lang.: EN Page 18 of20
Reviewed by: <Richard Zhang> Doc. Type: Manual Rev.: 1.0
App. by: <Howard Li> Sensitivity: <Internal> Document Status: Draft
MMECB User Manual
Primary Specific to application
SecondalY Specific to application
Class lOP
Burden 15VA
Voltage Transformer
ABB JDZX22
Type Dry
Primary Specific to application
Secondary Specific to application
Class 3P
Burden 50VA
Enclosure
Material Powder coat cold rolled steel sheets
Protection IP4X Indoor
Paint system Powder coat, RAL 7035
Safety Interlocking App lock
Installation Base fixing
Handling Crane lifting via lifting eye bolts on the roof
Cable entry Bottom
Power Factor Controller
ABB RVT
Measuring System Microprocessor-based system for single or three phase
system Insensitive to harmonics
Control Voltage 100Vac to 460Vac
Burden 15VA
Current input 5Aor IA
Alarm Contact I normally closedll normally open: 1.5A, 250VAC
Power Factor Setting 0.7 inductive to 0.7 capacitive
Communication Modbus (optional)
Over Current/Overload Protection Relay
ABB SPAJ140C#3
Measuring System Microprocessor-based
Control Voltage 80VAC to 265VAC
Burden 15VA
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Dept.: PPHV TC Doc. 10: <2GHVO 19795> Date: 2014-03-19
Prep. by: <Lucy Cheng> Lang.: EN Page 19 of20
Reviewed by: <Richard Zhang> Doc. Type: Manual Rev.: 1.0.
App. by: <Howard Li> Sensitivity: <Internal> Document Status: Draft
MMECB User Manual
Current input lAor 5A
Alarm/Trip signal Volt-free contacts
Under/Over- VoltagelUnbalance Protection Relay
ABB REU61 0 #3
Measuring System Microprocessor-based
Control Voltage 80VAC to 265VAC
Burden 15VA
Current input lor 5A
Alarm/Trip signal Volt-free contacts
CurrentNoltage Protection Relay
ABB REF615 #3
Measuring System Microprocessor -based
Control Voltage 80VAC to 265VAC
Burden 15VA
Current input 1 or 5A
Alarm/Trip signal Volt-free contacts
Capacitor unit Pressure switch ( optional)
Pressure setting 1 bar
Contact rating 4A,250VAC
Mechanical life 106 operations at 50 bar
Contact Type Changeover
Fuse Failure Indication (optional)
Contact Rating lOA, 125~250VAC
Contact type Changeover
Please refer to individual product brochures for detailed information on each component or contact ABB.
# Other control voltage please contact ABS.
#] Higher ratings available
#'2 Lower temperature ratings available
#3 Relay selections according to real case
8 Change Histories
Rev. Date Change Content Ch
<1.0> <2014-03-19> <Create document>
~ffl~~.~m~no
ftmum~*~~~~~m~~mA~~$~~opm.~*~~.~~~n~.
We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to
third parties without express authority is strictly forbidden.
2016.6.29