(4. (b. &) u Y d KUWAIT OIL COMPANY (K.S.C.)

Engineering Group

Specification Number 0 15-pH- 19 10

Cathodic Protection (CP) Transformer Rectifier Units

1

0

Rev

1 4 JUNE 9 4

7 MAR 9 2

Date

ISSUED AS KOC ENG. GROUP SPEC.

ISSUED FOR INVITATION TO BID

Revision BY Chkd Section PE

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Client

CONTENTS

E n g i d n g Grwp

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCOPE 3

STANDARD SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

BASIC ENGINEERING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . CONSTRUCTION REQUIREMENTS 5

INCOMING SUPPLY ISOLATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSFORMER 6

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RECTIFIER 7

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EARTHING 8

WIRING AND TERMINALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

CABLE TERMINATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

CONTROL AND PROTECTION EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . 10

ANTI-CONDENSATION HEATERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

CERTIFICATION OF ELECTRICAL EQUIPMENT FOR HAZARDOUS AREAS . 11

NAMEPLATES AND LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

PAINTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING 12

PACKING. MARKING AND DOCUMENTATION . . . . . . . . . . . . . . . . . . . . 12

SPARE PARTS AND MAINTENANCE REQUIREMENTS . . . . . . . . . . . . . . 12

Specification Number

01 5-PH-1910

Rev

1

Date

14-6-94

Sheet

2 of 12

Date Sheet I " I,..... I ..... E n g I d n g Group I S ' n

1.0 SCOPE

Specification Number

015-PH-1910 I ' I ' - - I J UI I L I

1.1 This specification covers the design, manufacture, testing and supply of cathodic protection transformer rectifier units for installation at the Facility in Kuwait.

1.2 The cathodic protection transformer rectifier units shall fully comply with all relevant contractual requirements specified in the Scope of Work and Technical Specification of the Contract.

2.0 STANDARD SPECIFICATIONS

2.1 Transformer rectifier units shall conform in design, materials and performance, except where otherwise specified, with the current issues and amendments of the following prevailing on the effective date of the Contract:

2.1.1 International Standards

IEC 51

IEC 76

IEC 79

IEC 146

IEC 185

IEC 186

IEC 255

IEC 269

IEC 439

IEC 947

Recommendation for Direct Acting Indicating Analogue Electrical Measuring Instrument and their Accessories

Power Transformers

Electrical Apparatus for ~ x ~ l o s i v e Gas Atmospheres

Semiconductor Converters

Current Transformers

Voltage Transformers

Electrical Relays

Low-Voltage Fuses

Low-Voltage Switchgear and Controlgear assemblies

Low-Voltage Switchgear and Controlgear

2.1.2 British Standard

BS 7361 Cathodic Protection: Code of Practice for Land and Marine Applications

2.1.3 Engineering Group Specifications

The cathodic protection transformer rectifier units shall conform with all relevant Engineering Group specifications of which the following are specifically referred to in this specification:

01 5-AH-1 001 Basic Design Criteria

01 5-AH-1 002 International Codes and Standards

01 5-KH-1902 Spare Parts and Maintenance Requirements

01 5-PH-1901 Electrical Design, Installation and Testing

01 5-PH-1903 Power Transformers

01 5-UH-1001 Packing, Marking and Documentation

01 5-WH-1006 Cathodic Protection Design Requirements

01 5-XH-1005 Shop and Field Painting

Compliance with this specification shall not relieve the Contractor of its responsibility to supply equipment suited to meet the specified service conditions and applicable regulations.

Where conflicts exist between this specification and other Drawings, standards, codes and specifications, the most stringent shall be applied.

Equipment may comply with other National Standards subject to receipt of prior written approval from the Company.

Q KOC Eng/&ng Grwp -n

3.0 SERVICE CONDITIONS

3.1 The equipment shall be suitable for continuous operation at a desert location under high ambient temperatures and humidity. The atmosphere at the Facility is generally dusty and corrosive and may contain traces of hydrogen sulphide.

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3.2 The transformer rectifier units shall be new and in all respects suitable for continuous operation in the service conditions stated in the Engineering Group Specifications entitled "Basic Design Criteria" and "Electrical Design, Installation and Testing" (Numbers 01 5-AH-1 001 and 01 5-PH-1901).

Specification Number

01 5-PH-1910

3.3 The transformer rectifier units shall be installed outdoors and the minimum degree of protection for enclosures in accordance with IEC 947 shall be as follows: Outdoor equipment assemblies - IP55.

Date

14-6-94

Rev

1

3.4 Reliability of all equipment to perform continuously in the service conditions specified is essential. Equipment typical of that being supplied shall have been in operational use elsewhere for a minimum of two years. Prototype

Sheet

4 of 12

or unproven equipment not having a well-established record shall not be considered.

3.5 All equipment including contactors, transformers, fuses, relay, all other current-carrying parts, all auxiliary devices, etc. shall have the specified ratings, which shall be their continuous rating as installed in the equipment after being suitably derated for the specified service conditions.

4.0 BASIC ENGINEERING INFORMATION

Unless otherwise specified, the transformer rectifier units shall be suitable in all respects for operation from a 440-V, 3-phase, 4-wire, 50-Hz supply.

The equipment shall be suitable for operation, without deleterious effect, subject to voltage and frequency variations according to the following: 4.2.1 Voltage st 6%.

4.2.2 Frequency * 2.5%.

4.2.3 Transient voltage depression down to 80% of rated voltage.

Electrical components for incorporation into the units shall comply with the relevant IEC standards. These shall be selected to exclude readily combustible insulating and constructional material and excessive heat generation. Electrical and mechanical reliability is of the utmost importance. The components shall have been type tested to the relevant IEC standard.

The rated maximum output shall not be less that 150% of the output required in the initial commissioning.

The output voltage and power rating selected for the transformer rectifier shall be subject to Company approval. Transformer rectifier units shall be located in safe areas. However, if a classified area location cannot be avoided, the equipment shall be certified as appropriate for the hazardous area.

5.0 CONSTRUCTION REQUIREMENTS

5.1 The transformer rectifier unit shall comprise a single structure accommodating the transformer, rectifier and control equipment.

5.2 Enclosure and tank construction shall be of the self-supporting, metal-clad type suitable for floor mounting.

5.3 Hinged access doors shall not exceed 900 mm wide. Individual hinged access doors shall be self-supporting, fastened by means of T-type key

QKK- Eng/&ng G m p n Speciflcatlon Number 015-PH-1910 Rev 1 Date 14-6-94 Sheet 5 0 f 12

Specification Number Rev Date Sheet Englrmdng Gmup QmMmtion 01 5-PH-1910 1 14-6-94 6of 12

lockable handle. Doors shall have facilities to restrain them in the open position.

The enclosure shall be constructed from folded and welded mild steel sheet not less than 2 mm thick. Cable access shall be via suitably sized 3 mm thick, removable, undrilled gland plates.

Enclosure and tank height shall not be greater than 2200 mm, and operating devices shall not be positioned higher than 1750 mm or lower than 500 mm from ground level.

The internal degree of protection provided by the enclosure against contact with live parts and ingress of solid bodies shall comply with IP2X minimum, according to IEC 947.

The enclosure and tank structure, including doors, shall be capable of withstanding internal pressures created by faults within the structure (equal to the maximum fault current rating) without danger to the operating personnel.

Enclosure and tank design shall comply with temperature rise limitations. Forced ventilation is unacceptable. Interlocks and covers shall be provided to prevent incorrect or unsafe operation and to prevent access to live parts.

Enclosure and tank design and construction shall facilitate inspection, cleaning, repair and maintenance and ensure absolute safety during operation, inspection and maintenance. The unit shall be provided with lifting eyes.

The units shall complete with oil sight gauge, silica gel breather, oil filter plug, drain valve, lifting lugs, and detachable metal shade of adequate size to serve as a rain shield and sunshade.

6.0 INCOMING SUPPLY ISOLATOR

The incoming AC supply isolator shall have a load-breaking, fault-making capacity in accordance with IEC 947, utilisation category AC23. The operating handle shall have onloff indication, be interlocked with the enclosure door and be padlockable in the off position.

7.0 TRANSFORMER

7.1 Transformer construction shall be of the oil-filled type, double wound, configured to suit the output rectifier, and shall comply with the requirements of IEC 76.

7.2 The transformer in-rush current shall be limited to five times the full load current.

7.3 Transformers shall be constructed in accordance with the Engineering Group Specification entitled "Power Transformers" (Number 01 5-PH-1903). However, in view of the low kVA ratings, the following facilities may be omitted:

7.3.1 Removable radiators. Radiators shall be fixed.

7.3.2 Conservator.

7.3.3 Buchholz relay.

7.3.4 Spring-loaded pressure relief device.

7.3.5 Oil and winding temperature detectors.

7.3.6 Current transformer provisions.

7.3.7 Disconnecting chambers.

7.4 The method of cooling shall be by natural circulation of oil natural, air natural (ONAN).

8.0 RECTIFIER

8.1 The rectifier shall include the following equipment:

AC supply indication.

DC output voltmeter.

DC output ammeter.

Output interrupt timer adjustable off 5 to 200 seconds and on 5 to 200 seconds.

A suitably rated surge and transient suppression protection for the diodes shall be placed across both AC input terminals to the rectifying elements and the DC output terminals from the rectifying elements.

The grade of silicon diodes used shall be such that the peak inverse voltage rating shall be above the voltage rating of the surge diverter.

8.2 The rectifier shall be of the manually controlled type and have a DC voltage and current rating to suit the design requirements of the cathodic protection system. The rectifier shall have a full-load efficiency of not less than 75%.

QKOC- Specification Number Rev Date Sheet Eng/&hg Group 015-PH-1910 1 14-6-94 80f 12 8.3 Output regulation shall be provided to allow for on-load variation of the

output. This regulation shall be achieved manually using 64 equal steps over the voltage range. The manual voltage regulation shall be easily accessible on the control panel.

8.4 The rectifier steady state DC output shall be controlled to within f 1 % of the set voltage, and the rms value of the ripple on the DC output voltage shall not exceed 5%.

9.0 EARTHING

An earth bar shall be provided along the full length of each enclosure. All metallic non-current carrying parts shall be bonded together and connected to the earth bar. External M I 0 earthing terminals shall be provided to facilitate connection of the enclosures to the earthing system.

Panel-mounted equipment with exposed metal parts such as indicating lights, pushbuttons and relays shall be separately earthed.

Provision shall be made for connecting the earth continuity conductors and cable armouring of all outgoing circuits.

Doors and hinged parts shall be bonded to the switchgear structure by means of a flexible copper connection having a minimum cross-sectional area of 6 mm2 arranged so that it cannot be trapped as the door is opened or closed.

Connections from the main earth bar to components shall consist of greenlyellow PVC-sheathed stranded copper conductors. Termination lugs shall be of the compression type.

10.0 WIRING AND TERMINALS

The transformer rectifier unit shall be supplied completely pre-wired to terminal blocks mounted at the bottom of the enclosure.

The internal wiring shall be carried out in a minimum of 1 .5-mm2 stranded copper conductor PVC-insulated 60011 000-V grade wires. Solid conductors shall not be used. Wiring shall be configured so that its insulation shall not be subject to injurious temperature. Internal wiring shall be adequately supported by either clamping of loomed runs or installed in plastic trunking; self-adhesive fixings are not acceptable. The support arrangement for wiring shall be such that they are not liable to cause permanent physical damage or deformation to the conductor or insulation. Wiring shall not be bent to a radius less than the permissible value given by the Approved Manufacturers. Trunking fill shall not exceed 75% of its capacity.

10.4 Internal wiring shall be identified by proprietary heat-shrinkable ferrules at each end, with numbers allocated by the Contractor. All wiring Drawings produced by the Contractor shall clearly identify the appropriate reference numbers. All wiring shall be terminated with approved crimped terminations.

10.5 Terminal blocks shall be arranged and installed to facilitate accessibility for cable core termination and inspection of terminal identification numbers. Except where otherwise specified, terminals shall be of the pinch-plate type, Klippon manufacture or Company-approved equivalent, suitable for a minimum conductor size of 1.5 mm2.

10.6 DC output terminals shall be post type, located near the bottom of the enclosure on a separate fixed panel and each post fitted with double nuts and washers. These terminal posts shall be made of a corrosion-resistant copper alloy. The number of terminals required shall be determined as part of the design.

10.7 Terminal posts shall have a minimum 76-mm clearance from each other and from all other metal parts.

10.8 Terminal blocks shall be logically grouped, indelibly marked and provided with removable plastic shrouds. Segregation of different voltage levels within terminal blocks shall be achieved by barriers. Voltage levels shall be clearly identified by labels.

10.9 No more than one wire shall be inserted into any one terminal. Looping between terminals, when required, shall be carried out using purpose-made top of block cross connection or comb-type busbar.

10.10 Terminal blocks associated with external sources of supply shall be fully shrouded and fitted with a danger warning label.

10.1 1 At least 300-mm clearance shall be allowed between the gland plate and any internal equipment to facilitate cable installation and connection.

10.12 Wire colours shall comply with the following:

440-VAC Phases Red, Yellow, Blue Neutral Conductor I Black

I 1 Earthing Conductor I Green I Yellow I AC Control Wiring Black DC Control Wiring I Grey

I DC Supply Positive I Red or Grey with Red markers

I I I DC Supply Negative I Black or Grey with Black markers I

11.0 CABLE TERMINATIONS

Q KOC Engineering Group SpdfiWbn 11.1 Undrilled removable gland plates shall be provided on cable termination

compartments.

11.2 All cable entries shall be from bottom and all connections shall be made from the front of the panel.

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Specification Number

015-PH-1910

11.3 The terminals shall be arranged so that dressing and connecting of cables can be done safely, and without exposure to adjacent live functional units.

11.4 Inside the compartments separate terminals or bolts of adequate dimensions, one for each cable, shall be fitted for cable armouring earthing purposes.

Rev

1

12.0 CONTROL AND PROTECTION EQUIPMENT

12.1 The rectifier output and control circuits shall be protected by fuses.

Date

14-6-94

12.2 All control switches shall be of the rotary-key, lockable type, fitted with suitably rated contact blocks.

Sheet

10 of 12

12.3 Indication lamps shall be of the low-power consumption, filament or LED type, visible from a wide viewing angle in normal lighting conditions and shall have fully shrouded rear terminals.

12.4 Filament-indicating lamps shall be provided with a series resistor sized to drop 20% of rated voltage and having a power rating corresponding to lamp shorted condition.

12.5 A lamp test pushbutton shall be incorporated on the front of the cubicle.

12.6 Analogue-indicating instruments shall be the 72-mm square flush type and comply with IEC 51, Class 1 and have 240 scale movements. The instruments shall be back connected and have external zero adjustment. The minimum scale reading shall not be less than 20% of the normal or full- load reading. All facias shall be white and pointers black; scale shall be in actual values. A red line or adjustable red pointer to indicate the normal operating point shall be provided.

12.7 Digital displays shall be accurate to at least * 1 V or * 1 amp. Metering and indication shall be corrected to read true rms values of voltage and current.

12.8 Silicon diodes shall be protected by high-speed fuses.

12.9 Fuses shall be of the HRC type according to IEC 269 and fitted in fully insulated carriers and bases.

13.0 ANTI-CONDENSATION HEATERS

Space heaters, controlled by thermostats, shall be provided for enclosures containing electronic components. Heaters with isolating switch fuse and neutral link shall be suitable for 250-V, single-phase supply from an external source. Surface temperature of all heaters shall not exceed 160C.

14.0 CERTIFICATION OF ELECTRICAL EQUIPMENT FOR HAZARDOUS AREAS

Transformer rectifier units for installation in Zone 1 and Zone 2 hazardous areas shall be certified for use in those areas by a recognised CENELEC Testing Authority or other Authority approved by the Company.

15.0 NAMEPLATES AND LABELS

Each unit and main sub-assembly shall have a nameplate clearly and indelibly marked with the data specified in the appropriate IEC standard. Nameplates shall be fixed with non-corrodible screws or rivets.

The data on the nameplate shall include as a minimum:

15.2.1 Manufacturer's name, serial number and year.

15.2.2 Equipment designation number.

15.2.3 Supply rating data: voltage, current, kVA, frequency etc.

15.2.4 Rated output voltage and current.

1 5.2.5 Temperature classification.

15.2.6 Hazardous area classification if appropriate.

The unit shall have a label on its front at high level showing the unit designation number.

An engraved instruction notice shall be affixed to the equipment in a prominent location. The notice shall list procedures to be employed in switching for startup, shutdown, maintenance and test operations.

Warning labels shall be provided in all locations where necessary to warn personnel of potentially dangerous situations.

All instruments, selector switches, indicators, etc, shall be provided with descriptive labels.

All solid state or other equipment which can be damaged when subjected to high voltage shall be provided with a warning label stating that they must not be subjected to high-voltage tests.

15.8 Labels shall have black characters on a white background, except warning labels shall have white characters on a red background.

15.9 All labels shall be engraved on plastic-laminated material and secured with non-corrodible screws. Adhesive or self-tapping screws are unacceptable.

15.10 All components incorporated within the unit shall be indelibly marked with the component circuit reference. Handwritten stickers or dyno-tape labels are unacceptable.

16.0 PAINTING

Painting shall be in accordance with the Engineering Group'specification entitled "Shop and Field Painting" (Number 01 5-AH-1 001 ).

17.0 TESTING

17.1 The tests listed below shall be performed at the Approved Manufacturer's Works.

17.2 Tests shall be carried out in accordance with the relevant IEC standards and shall include as a minimum:

17.2.1 Insulation test of all circuits (except semiconductor components). 17.2.2 Full functional test.

17.2.3 Full load duration test to establish thermal stability of the unit (48 hours).

17.2.4 Short circuit test to prove current limiting capability of rectifier.

17.3 The following measurements shall be carried out at 0%, 50% and 100% of full-load direct current and shall be repeated at plus 10% and minus 10% of the nominal supply voltage:

17.3.1 Output voltage ripple.

17.3.2 DC output current.

18.0 PACKING, MARKING AND DOCUMENTATION

For all relevant requirements, refer to the Engineering Group Specification entitled "Packing, Marking and Documentation" (Number 01 5-UH-1001).

19.0 SPARE PARTS AND MAINTENANCE REQUIREMENTS

For all relevant requirements, refer to the Engineering Group Specification entitled "Spare Parts and Maintenance Requirements" (Number 01 5-KH-1902).