erection operation & maintenance manual for 415v, 3000a nspbd

Upload: thegemishere

Post on 09-Oct-2015

128 views

Category:

Documents


4 download

DESCRIPTION

C&S NSPBD Manual

TRANSCRIPT

  • C&S Electric Ltd

    B-1, Site-IV, Surajpur Industrial Area, Kasna Road, Greater Noida.

    Dist :- G.B. Nagar (U.P.)

    Ph. No. :- 91-0120-3914500-01 Fax No. 91-0120-2341896

    Website : www.cselectric.co.in

  • APPDCHKDREVISIONSDATE BY

    FOR 415V, 3000A

    NON-SEGREGETED PHASE BUSDUCT

    TITLE OF THE DOCUMENT

  • Project : 1x125 MW Concentrated Solar Thermal Power Project Jaisalmer, Rajasthan Doc. No.: 5427PN050-DHU-E-MRS-LVS-XXX-XXX Rev 00 C&S Doc.No.: C-1410-0712-16507 Doc Title: - Erection, Operation & Maintainanace Manual for 415V, 3000A Non-Segregated Phase Busduct.

    C&SElectric Ltd. 2

    CONTENTS

    PART NO DESCRIPTION PAGE NO.

    I SALIENT FEATURES OF BUSDUCTS 3-4

    II FACTORY ASSEMBLY AND ROUTINE TESTS 5

    III MATERIAL RECEIPT 5

    IV STORAGE 6

    V PRE-ERECTION 6

    VI ERECTION 7-12

    VII PRE-COMMISIONING 13

    VIII POST COMMISIONING 14-15

    IX OPERATION & MAINTENANCE 16

    XI FIELD TESTS 17

    XII DOS AND DONTs 17

    XII MAINTENANCE SCHEDULE 18

    XIV APPROVED DRG. MDL 19

  • Project : 1x125 MW Concentrated Solar Thermal Power Project Jaisalmer, Rajasthan Doc. No.: 5427PN050-DHU-E-MRS-LVS-XXX-XXX Rev 00 C&S Doc.No.: C-1410-0712-16507 Doc Title: - Erection, Operation & Maintainanace Manual for 415V, 3000A Non-Segregated Phase Busduct.

    C&SElectric Ltd. 3

    Part-I-SALIENT FEATURES OF BUSDUCTS The Busducts serve as interconnections between Transformer and LT Panel (Switchgear). These are of Non-

    segregated Phase type. The Busducts are natural air cooled for Outdoor and Indoor purpose.

    ENCLOSURE:- The Enclosures are rectangular in cross section and are fabricated out of Al Alloy Sheets. Adjacent sections of

    the Busducts are connected by means of Bolts and nuts with gasket in between to render the Busduct dust and

    vermin proof.

    BUSBAR:- Al Alloy flats (PVC Sleeved) are used as busbars with Painted Matt black colour except contact surface.

    Busbars are designed to meet the thermal and dynamic rating of Busduct. The final temperature of the Busbars

    is limited to 950C the specified requirements.

    BUSBAR SUPPORTS:- Bus supports are FRP plate having adequate electrical and mechanical characteristics. The Busbars are

    supported on the FRP plate in such a way as to allow free movement of busbars due to thermal variations. FRP

    supports are suitably spanned to with stand mechanical forces that are likely to act during short circuit.

    BUSBAR RIGID JOINT:- Bolted overlap type Busbar rigid joints are envisaged for connecting successive Busbars of the same phase. HTS

    bolts, nuts and spring steel washers are used to achieve an efficient joint.

    INSPECTION OPENING:- Bolted type inspection openings of sufficient size are provided on the enclosures to facilitate maintenance of

    busbar supports and busbar joints.

    RUBBER BELLOW:- EPDM rubber bellows are provided at transformer end terminations. These will provide flexibility in erection

    and also take care of settlement of Transformer / Switchgear connections.

  • Project : 1x125 MW Concentrated Solar Thermal Power Project Jaisalmer, Rajasthan Doc. No.: 5427PN050-DHU-E-MRS-LVS-XXX-XXX Rev 00 C&S Doc.No.: C-1410-0712-16507 Doc Title: - Erection, Operation & Maintainanace Manual for 415V, 3000A Non-Segregated Phase Busduct.

    C&SElectric Ltd. 4

    WALL FRAME ASSY:- Wall frame assembly with FRP sealing pale provided at the location crossing the busduct Transformer yard / room to switchgear room for prevent of any fire in equipment to other equipment, Sealing plate also stop the air from outdoor to indoor. Silica gel breathers are provided at both side of sealing plate for any absorbing any moisture. TERMINATIONS

    TRANSFORMER & PANEL END TERMINATION:- Busducts are terminated on to the Transformer / Switchgear by means of copper laminated Flexibles HTS bolts,

    nuts and washers are used to achieve an efficient joint.

    SPACE HEATERS:- Space heaters are provided at regular intervals in the run of the Busduct enclosure for complete run of

    Busducts. These can be removed or replaced without disturbing the bus arrangement. All the space heaters are

    wired to a common marshalling box provided at suitable locations at Panel side adaptor Box.

    MARSHALLING BOX:- Space heater wiring is envisaged by 2.5 mm2 copper wires running through PVC conduits. The Marshalling box

    is made of Al alloy and space heaters are wired to it.

    GROUNDING:- Al earth bus size-1 Nos 50x10 thk. flats are provided along the entire run of the Busduct at single side of

    enclosure bottom edge line. Provision is made for connecting the ground bus at the equipment ends. All ground

    bus joints are made with MS electro galvanised bolts and nuts.

    PAINTING:- The exterior of the enclosure is painted Epoxy based (Indoor with RAL 7032 & Outdoor with 631 of IS : 5), for

    enclosure interior and busbar painted with Matt black paint.

    ********

  • Project : 1x125 MW Concentrated Solar Thermal Power Project Jaisalmer, Rajasthan Doc. No.: 5427PN050-DHU-E-MRS-LVS-XXX-XXX Rev 00 C&S Doc.No.: C-1410-0712-16507 Doc Title: - Erection, Operation & Maintainanace Manual for 415V, 3000A Non-Segregated Phase Busduct.

    C&SElectric Ltd. 5

    Part-III-FACTORY ASSEMBLY & ROUTINE TESTS

    Before assembly of various Busduct sections detailed study of Layout / Erection & Key diagram and other

    contract drawings should be made to ensure no part of Busduct is missed. The Busducts after assembly must be

    checked for fouling and clearances. Power frequency high voltage test must be conducted on entire assembly as

    routine tests.

    After completion of the tests Busducts have to be dismantled and each Busduct sections should be separately

    kept in a casing with a packing list. All assemblies must have erection marks clearly marked up.

    Part-IV-MATERIAL RECEIPT (UNLOADING, INSPECTION & HANDLING) 1, Proper crane/sufficient manpower shall be employed for unloading the packing from the trucks/wagons.

    Under no circumstances should the packing be rolled/ pushed down the wagons/trucks.

    2, Make a thorough inspection of the complete consignment for verification of quantity and external damages.

    If any damage is found or suspected, report at once with particulars.

    3, During unloading and handling operation if loose parts are found in the bottom of equipment, preserve them

    for re-assembly or replace them in the respective locations.

    4, While uncrating the packages, sufficient care shall be taken to avoid damages due to sharp crowbars or

    opening levers.

    5, Contents of the case/crate shall be verified with the packing slip kept inside the package.

    6, The structures shall be clean, free from sharp edges, bends etc. The external damages to galvanizing due to

    rough handling or unusual weather conditions or any other cause shall be verified.

    7, All packages shall be handled gently as the busducts may be sent partly assembled with insulators.

    8, Entire quantity of enclosures, elements, loose items etc. shall be received as per the packing list.

    9, The enclosures shall not have any external damages or deformation. If the flange edges are damaged,

    gaskets and the retaining arrangement will not effectively seal the enclosures.

    10, The enclosure surface shall be free from dents, scratches on the painted surface and at welded joints.

    11, The Busbars support shall be verified for any cracks, etc.

    12, All the inspection covers shall be tightly closed with proper gaskets inside.

    13, The enclosures are to be checked for presence of any foreign material inside.

    14, Water or any deposits inside the enclosure shall be thoroughly cleaned.

    15, The items which are made of Aluminum or soft materials shall be handled very carefully to avoid any

    damage at site.

    16, Ensure that the assemblies/components are put back in the original packing as in received condition before

    sending them for storage.

    ********

  • Project : 1x125 MW Concentrated Solar Thermal Power Project Jaisalmer, Rajasthan Doc. No.: 5427PN050-DHU-E-MRS-LVS-XXX-XXX Rev 00 C&S Doc.No.: C-1410-0712-16507 Doc Title: - Erection, Operation & Maintainanace Manual for 415V, 3000A Non-Segregated Phase Busduct.

    C&SElectric Ltd. 6

    Part-V-STORAGE

    1, All assemblies/components shall be properly packed in the original packing with suitable polythene

    covers.

    2, All packages must be kept in well protected areas.

    3, All small fragile items must be stored in proper containers at safe locations to avoid any damage.

    4, Identification marks or tags shall be kept for easy identification.

    5, All the items shall be stored in a systematic way for easy removal and to avoid any damage.

    6, The heavy packages shall be stored one above the other.

    7, Suitable slings shall be used to avoid impact on the packages while handling.

    8, The structure shall not be laid directly on the ground and should be stacked on wooden battens to avoid

    direct contact with soil or water.

    9, The Hardware such as Bolts, Nuts & Washers shall be stored in indoor and kept size wise in racks

    preferably with a coating of oil in separate compartment for easy identification.

    10, Enclosure, Busbars & FRP shall be protected carefully.

    11, Inspection covers shall be tightly closed to avoid entry of dust and water.

    12, Rubber bellows shall be stored in such a way to avoid direct contact with heat and sharp materials, which

    will damage the same.

    13, Flexibles shall be well protected from any damage.

    Part-VI-PRE ERECTION 1, All documents especially bill of material, layout drawings for busducts and structures shall be kept

    readily available.

    2. All the tools and tackles shall be made available. All civil details and equipment locations are checked

    thoroughly to ensure perfect matching of busduct sections as per field quality assurance manual.

    3. The rubber bellows shall be in good condition, and made ready for assembly/erection.

    4. The FRP and the busbars shall be thoroughly cleaned with dry air before and after the assembly.

    5. The ends of busbars shall be smooth and free from dust, dents and paint etc.

    6. The inside of enclosure shall be cleaned and free of foreign materials.

    7. All surfaces that are to be bolted of busbars and earth bus etc. shall be thoroughly cleaned and free of

    foreign materials.

    ********

  • Project : 1x125 MW Concentrated Solar Thermal Power Project Jaisalmer, Rajasthan Doc. No.: 5427PN050-DHU-E-MRS-LVS-XXX-XXX Rev 00 C&S Doc.No.: C-1410-0712-16507 Doc Title: - Erection, Operation & Maintainanace Manual for 415V, 3000A Non-Segregated Phase Busduct.

    C&SElectric Ltd. 7

    Part-VII- ERECTION

    GENERAL Before the erection of busducts at site the Layout / Erection and Key / Assembly Drawings shall be studied in

    detail and an easy and better procedure shall be developed. If the materials have been stored properly with

    correct inventory, the installation work can proceed without the delay in searching for missing parts.

    It is always preferable to begin the work at one end proceed to the other end. At this juncture, check up whether

    necessary arrangements are provided at Switchgear / Transformer terminals for terminating Busducts use proper

    tools like tirfor, pulley block etc. for lifting the enclosures. Proper selection of pulleys (2 or 3 sheaves) with

    good quality manila ropes will improve the mechanical advantage and minimize the strain to erection crew

    particularly when busducts are to be installed at high elevations.

    Stringing the busducts for lifting and moving shall be done by skilled erectors and it shall be supervised that the

    strings are provided properly so that the enclosures are lifted in a balanced manner without giving chance for

    slip off. Check for the correctness of erection number on the enclosure before lifting and erecting the same in

    the proper location. All enclosures must be in position and alignment should be checked before proceeding with

    the bolting of busbars.

    After the bus and support housings are in position, the FRP shall be wiped clean and all dust and foreign matter

    removed from inside the enclosures. During the assembly, all the open portions of the bus enclosures shall be

    protected from the accumulation of dust or dirt. Provision shall be made to prevent the entry of dust into the

    portion of the enclosures, which have been erected.

    SUPPORT STRUCTURES 1. Check up whether all foundation for steel columns have been cast and fixing plates have been embedded.

    2. A thorough study of Layout / Erection & Key diagram is essential before taking up the steel erection. It

    shall be ensured that all elevations are as per the drawing and any deviation shall be brought to the notice

    of the customer. Under no circumstance the column erection should commence until the elevations match

    with the approved drawings.

    3. After ascertaining the correct location of embedded plates, weld the studs and fill up the gap between the

    plate and floor with lean concrete or plaster such that the surface is in flush with the finished floor with

    only studs projecting out.

    4. Install supporting members in their respective places.

    5. Verify with the drawings frequently to ensure correct installation of structures.

    6. Keep the transverse member in position and tighten them after ascertaining the correct location.

    7. Avoid using twisted member. This will cause great difficulty while aligning the enclosures.

  • Project : 1x125 MW Concentrated Solar Thermal Power Project Jaisalmer, Rajasthan Doc. No.: 5427PN050-DHU-E-MRS-LVS-XXX-XXX Rev 00 C&S Doc.No.: C-1410-0712-16507 Doc Title: - Erection, Operation & Maintainanace Manual for 415V, 3000A Non-Segregated Phase Busduct.

    C&SElectric Ltd. 8

    8. Ensure all members of structures are properly grounded.

    ENCLOSURE Each standard enclosure is provided with two supports, one at either end. The site assembly work should start

    from a fixed position. This may be from either the transformer or switchgear terminals. If there is a wall / floor

    crossing, the erection work may also be commenced from this place, after checking thoroughly the correctness

    of the position of the wall / floor opening.

    BOLTING OF ENCLOSURE:- The complete busduct is aligned and correct positioning at reference points such as transformer terminals, wall /

    floor crossing, Switchgear terminals etc. is ensured. Connections between successive enclosures are done by

    bolting with a EPDM gasket in between enclosure flanges. All inspection openings on the enclosures shall be

    closed the moment the corresponding busbar joints are completed.

    BUSBARS Before proceeding with the busbar assembly, the FRP shall be thoroughly checked for any mechanical damage

    during transit. Further it is desirable to megger the individual busduct sections before joining them together. If

    poor results are obtained, the FRP are to be checked. Meggering the FRP sheets at the initial stage will avoid

    replacement of FRP after the final assembly of busducts, which is laborious and time consuming.

    For bolted joints in busducts, the following joining procedure should be adopted.

    JOINING PROCEDURE

    FOR BOLTED JOINTS:- 1. Apply a thin film of suitable grease on the joint surfaces busbar and splice plate. Rub with steel wool on

    the greased joint surface. Wipe away with a clean cloth.

    2. The surface will have a silvery gleam which will contrast with the surface to the aluminum not cleaned

    then apply `Multipurpose grease at once, on the joint surface (any delay should be avoided to prevent re-

    oxidization).The coating should be approx. 1mm thick and should cover the entire contact area.

    3. Tighten the bolts after keeping the contact surfaces correctly in position. While tightening, ensure a

    generous squeeze of the grease from the joint. If sufficient grease does not appear, disconnect and apply

    additional grease and then tighten.

    4. Bolts & nuts which are supplied with spring washers shall be tightened initially with spanners and finally checked with torque wrench for the recommended values, which are furnished below:

    5. Bolt tightness Torque values:

  • Project : 1x125 MW Concentrated Solar Thermal Power Project Jaisalmer, Rajasthan Doc. No.: 5427PN050-DHU-E-MRS-LVS-XXX-XXX Rev 00 C&S Doc.No.: C-1410-0712-16507 Doc Title: - Erection, Operation & Maintainanace Manual for 415V, 3000A Non-Segregated Phase Busduct.

    C&SElectric Ltd. 9

  • Project : 1x125 MW Concentrated Solar Thermal Power Project Jaisalmer, Rajasthan Doc. No.: 5427PN050-DHU-E-MRS-LVS-XXX-XXX Rev 00 C&S Doc.No.: C-1410-0712-16507 Doc Title: - Erection, Operation & Maintainanace Manual for 415V, 3000A Non-Segregated Phase Busduct.

    C&SElectric Ltd. 10

  • Project : 1x125 MW Concentrated Solar Thermal Power Project Jaisalmer, Rajasthan Doc. No.: 5427PN050-DHU-E-MRS-LVS-XXX-XXX Rev 00 C&S Doc.No.: C-1410-0712-16507 Doc Title: - Erection, Operation & Maintainanace Manual for 415V, 3000A Non-Segregated Phase Busduct.

    C&SElectric Ltd. 11

  • Project : 1x125 MW Concentrated Solar Thermal Power Project Jaisalmer, Rajasthan Doc. No.: 5427PN050-DHU-E-MRS-LVS-XXX-XXX Rev 00 C&S Doc.No.: C-1410-0712-16507 Doc Title: - Erection, Operation & Maintainanace Manual for 415V, 3000A Non-Segregated Phase Busduct.

    C&SElectric Ltd. 12

    SPECIFIED INSTRUCTIONS : 1. Proper tools shall be used for transportation of materials.

    2. The required assemblies or components alone shall be taken to erection site at each stage of erection.

    3. The fragile item shall be handled carefully.

    4. The structures shall be properly tightened after alignment.

    5. The lifting slings shall be put properly to avoid any distortion and ensure temporary supports if necessary

    are ready before lifting the busducts.

    6. The floor frame assembly shall be assembled with gaskets properly before lifting to its position.

    7. Enclosure sections and rubber bellows shall be properly placed & busbars shall be checked.

    8. Before making the joints the cleanliness of jointing ends of busbars shall be checked.

    9. Proper application of contact grease is necessary for busbar ends before jointing.

    10. The bolts shall not be hammered but tightened fully to the required torque without over tightening.

    11. The clearances between phase and enclosures shall confirm to the design values throughout the busducts.

    12. Insulators and seal off bushings shall be checked for any damage.

    13. No foreign materials or tools shall be left inside the enclosure.

    14. All inspection covers shall be properly tightened with gaskets inside and the rubber bellows shall be

    connected properly.

    15. The earthing of busducts and structures shall be done properly.

    16. If Transformer or switchgear connections are to be done later ensure that the enclosure ends are covered

    properly.

    17. Painting touch up if required shall be done for entire run of busducts.

    ********

  • Project : 1x125 MW Concentrated Solar Thermal Power Project Jaisalmer, Rajasthan Doc. No.: 5427PN050-DHU-E-MRS-LVS-XXX-XXX Rev 00 C&S Doc.No.: C-1410-0712-16507 Doc Title: - Erection, Operation & Maintainanace Manual for 415V, 3000A Non-Segregated Phase Busduct.

    C&SElectric Ltd. 13

    PART-VII-PRE COMMISIONING 1. All pre-commissioning tests shall be conducted for busducts as per the field quality assurance. 2. Power frequency withstand tests shall be made in the field at 80% of the values given below:

    Nominal Voltage inV(RMS) Power Frequency withstand(1 minute dry) in KV(RMS)

    415 2.5

    3. All joints have to be made properly tightened with correct bolt and nuts. Ensure that no joints have been

    left without bolts.

    4. All bolts and nuts have to be properly tightened.

    5. There shall not be any bending/buckling of structure members.

    6. All the structures shall be properly earthed to the station ground bus.

    7. The temporary supports of busbars inside the enclosures if any shall be removed.

    8. The Porcelain and FRP shall be verified for breakage etc.

    9. The interior of the enclosures, busbars, FRP/sealing shall be cleaned and free from dirt, oil, grease or any

    deposits and moisture.

    10. Ensure that no flexible laminations have come out protruding and sharp corner is left anywhere.

    11. Ensure all bolts and nuts at every flange joints and inspection covers are properly tightened.

    12. The gaskets shall be provided at every flange joints and the inspection covers.

    13. Proper earthing of busducts and support structures with station earthing system shall be done.

    14. The wiring and terminal clamps in the marshalling boxes and space heater/ thermostat shall be checked for

    correctness.

    15. The space heaters and thermostat shall be in good working condition.

    ********

  • Project : 1x125 MW Concentrated Solar Thermal Power Project Jaisalmer, Rajasthan Doc. No.: 5427PN050-DHU-E-MRS-LVS-XXX-XXX Rev 00 C&S Doc.No.: C-1410-0712-16507 Doc Title: - Erection, Operation & Maintainanace Manual for 415V, 3000A Non-Segregated Phase Busduct.

    C&SElectric Ltd. 14

    PART-VIII- POST COMMISIONING All precautions normally observed for High Tension Apparatus should be taken when inspecting Non

    Segregated Phase Busduct and associated equipments. Housing should never be opened unless the entire unit is

    shut down and the personnel working on the equipment assure themselves that the busduct is not live.

    The only reason for opening the bus housing is to clean the FRP to check the space heaters and to ensure if any

    loose contact is there in wiring. The first time the unit is shut down, a set of inspection covers in Indoor area

    may be removed to determine the amount of dust collected. If this is appreciable, further inspection should be

    made and insulators cleaned. If the insulators are clean the interval of inspection can be lengthened. Normally,

    the inspection would have to be made more often than yearly intervals. However, the frequency of inspection

    should be based on local conditions. Much longer intervals could safely be expected unless local atmosphere has

    a very large amount of suspended dust. Space heater can be removed and replaced by suitably opening the

    inspection covers.

    It is recommended that during the annual maintenance for the equipments like transformer etc. the busducts

    also should be checked for dust collection, insulation resistance values, tightness of all bolts and nuts and spring

    washers etc. It is desirable to change the busduct gaskets one in 5 years if they are found hard and brittle.

    The tightness of busbar joints should be checked during this period with the help of torque wrench. Sufficient

    amount of `Multiple-Purpose grease also should be applied at the joining surfaces. The Flexibles used at

    Transformer, Switchgear terminals should also be checked for any abnormal temperature rise.

    As already stated, the frequency of inspection should be decided based on the amount of dust collection. Besides

    this, there is no need to have quarterly/half yearly maintenance checks. But it is preferable to inspect all joints

    and FRP at least once in a year.

    Since the busbars are enclosed, no failure is expected. Expected failure, which may occur, is at support FRP,

    either due to dust collection and condensation or due to minor cracks. In such events, the FRP must be cleaned

    and the busbars to be hipoted before commissioning. If FRP do not withstand the hi-pot, then replace them with

    new ones. If the busducts are inspected and maintained periodically there can be no chance of any failures.

  • Project : 1x125 MW Concentrated Solar Thermal Power Project Jaisalmer, Rajasthan Doc. No.: 5427PN050-DHU-E-MRS-LVS-XXX-XXX Rev 00 C&S Doc.No.: C-1410-0712-16507 Doc Title: - Erection, Operation & Maintainanace Manual for 415V, 3000A Non-Segregated Phase Busduct.

    C&SElectric Ltd. 15

    SPECIFIC INSTRUCTIONS :- 1. Proper tools and plants shall be used for transporting materials.

    2. The required assemblies or components alone shall be taken to erection site at each stage of erection.

    3. The fragile item shall be handled carefully.

    4. The structures shall properly tightened after alignment.

    5. The lifting slings shall be put properly to avoid any distortion and ensure temporary supports if necessary

    are ready before lifting the busducts.

    6. The floor assembly shall be assembled and gasket properly before lifting to its position.

    7. Enclosure sections and rubber bellows shall be properly placed and busbars checked.

    8. Before making the joints the cleanness of jointing ends of busbars shall be checked.

    9. Proper application of contact grease is necessary for busbar ends before jointing.

    10. The bolts shall not be hammered but tightened fully to the required torque without over tightening.

    11. The clearances between phase and enclosures shall confirm to the design values throughout the busducts.

    12. FRP and sealing shall be checked for any damage.

    13. No foreign materials or tools shall be left inside the enclosure.

    14. All inspection covers shall be properly tightened with gaskets inside and the rubber bellows shall be

    connected properly.

    15. The earthing of busducts and structures shall be done properly.

    16. If transformer or switchgear connections are to be done later ensure that the enclosure ends are covered

    properly.

    17. Painting touch up, if required shall be done for entire run of busducts for good physical appearance of the

    assembly.

    *********

  • Project : 1x125 MW Concentrated Solar Thermal Power Project Jaisalmer, Rajasthan Doc. No.: 5427PN050-DHU-E-MRS-LVS-XXX-XXX Rev 00 C&S Doc.No.: C-1410-0712-16507 Doc Title: - Erection, Operation & Maintainanace Manual for 415V, 3000A Non-Segregated Phase Busduct.

    C&SElectric Ltd. 16

    PART-IX-OPERATION & MAINTENANCE All precautions normally observed for High Tension Apparatus should be taken when inspecting Non

    Segregated Phase Busduct and associated equipments. Housings should never be opened unless the entire unit is

    shut down and the personnel working on the equipment assure themselves that the busduct is not live.

    The only reason for opening the bus housing is to clean the FRP, sealing plate and to check the space heaters

    and to ensure if any loose contact in wiring. The first time the unit is shut down, a set of inspection covers in

    Indoor area may be removed to determine the amount of dust collected. If this is appreciable, further

    inspection should be made and insulators cleaned. If the insulators are clean, the interval of inspection can be

    lengthened. Normally the inspection would have to be made often than yearly intervals. However the frequency

    of inspection should be based on local conditions. Much longer intervals could safely be expected unless local

    atmosphere has a very large amount of suspended dust. Space heater can be removed and replaced by suitably

    opening the inspection covers.

    It is recommended that during the annual maintenance for the equipments like transformer etc. the busducts also

    should be checked for dust collection, FRP resistance values, tightness of all bolts and nuts and spring washers

    etc. It is desirable to change the busduct gaskets once in 5 years if they are found hard and brittle.

    The tightness of busbar joints should be checked during this period with the help of torque wrench. Sufficient

    amount of `Multi-Purpose grease also should be applied at the joining surfaces. The Flexibles used at

    Transformer and Switchgear Terminations should also be checked for any abnormal temperature rise. Replace

    if necessary, bimetallic strips, ensure that no flexible connecting bolt is loose due to vibration.

    As already stated, the frequency of inspection should be decided based on the amount of dust collection.

    Besides this, there is no need to have quarterly / half - yearly maintenance checks. But it is preferable to inspect

    all joints and the insulators at least once in a year.

    Since the busbars are enclosed, no failure is expected often except failure of insulation. This will occur at

    support FRP/ sealing, either due to dust collection and condensation or due to minute cracks. In such events, the

    bushings must be cleaned and the busbars to be hi -poted before commissioning. If FRP / sealing plate do not

    withstand the Hi- pot, then replace them with new ones. If the busducts are inspected and maintained

    periodically there can be no chance of any failures.

    ********

  • Project : 1x125 MW Concentrated Solar Thermal Power Project Jaisalmer, Rajasthan Doc. No.: 5427PN050-DHU-E-MRS-LVS-XXX-XXX Rev 00 C&S Doc.No.: C-1410-0712-16507 Doc Title: - Erection, Operation & Maintainanace Manual for 415V, 3000A Non-Segregated Phase Busduct.

    C&SElectric Ltd. 17

    Part-XI-FIELD TESTS The following are the suggested field tests to be conducted on the Busduct:-

    Open inspection covers and check bus conductor joint bolts with the help of Torque Wrench. Ensure at least

    10% of the joint locations are checked. Check up for any possible gaps between surfaces by using feeler gauge.

    Dielectric Tests Power Frequency withstand tests can be made in the field at 80% of the values given

    Nominal Voltage Power Frequency Withstand

    (1 Minute Dry)

    415 V 2.5 KV

    Precautions for Conducting Power Frequency Tests 1) Disconnect termination of enclosure and Bus conductor at Transformer/Generator.

    2) Cordon off the entire Segregated Phase Busduct area.

    Part-XII-Dos & Donts D0's

    1. Clean the insulators, seal off bushings, drain plugs etc periodically as noted.

    2. Check for tightness of busbar joints and grease them suitably.

    3. Ensure the functioning of space heaters and thermostats.

    4. Ensure the quality of the EPDM rubber gasket and change the same with a new one at periodic inspection

    if found necessary.

    5. Check effectiveness of joints at rubber bellows to avoid seepage of water.

    6. Check effectiveness of earth continuity.

    7. Enclosure exterior painting may be done once in five years.

    DON'Ts

    1. Do not open any of the inspection opening covers when the unit is live.

    2. Do not walk over the busduct.

    3. Do not disconnect any of the earth connection during maintenance.

    4. Do not open rubber bellow with sharp edged tools.

    5. Do not use sharp tools while doing maintenance work at equipment termination to avoid any damages.

    *******

  • Project : 1x125 MW Concentrated Solar Thermal Power Project Jaisalmer, Rajasthan Doc. No.: 5427PN050-DHU-E-MRS-LVS-XXX-XXX Rev 00 C&S Doc.No.: C-1410-0712-16507 Doc Title: - Erection, Operation & Maintainanace Manual for 415V, 3000A Non-Segregated Phase Busduct.

    C&SElectric Ltd. 18

    MAINTENANCE SCHEDULE

    No. ITEM TO BE

    INSPECTED

    INSPECTION

    NOTES

    ACTION REQUIRED IF

    INSPECTION SHOWS

    UNSATISFACTORY

    RESULTS

    FREQUENCY

    1. Busbar Support

    (FRP )

    Check for dirt Clean Annual

    2. Busbars joints and

    terminations.

    Check for bolt

    tightness.

    Tighten the bolts for required

    level. Apply grease if required.

    Annual

    3. Insulation resistance. Check for I.R.

    value between

    busbar and

    enclosure &

    between busbars.

    If the I.R. value is less than 0. 5

    Mega Ohm when measured

    with a 1000V Mega Ohm

    Meter, it is recommended to

    take out the FRP and clean the

    same and recheck for IR value.

    Annual

    4. Rubber bellows &

    gaskets

    Check for

    brittleness

    If the same is found too brittle

    the same needs replacement

    Once in 3 years

    *******

  • Project : 1x125 MW Concentrated Solar Thermal Power Project Jaisalmer, Rajasthan Doc. No.: 5427PN050-DHU-E-MRS-LVS-XXX-XXX Rev 00 C&S Doc.No.: C-1410-0712-16507 Doc Title: - Erection, Operation & Maintainanace Manual for 415V, 3000A Non-Segregated Phase Busduct.

    C&SElectric Ltd. 19

    AS BUILT/APPROVED DRAWING

  • SL. NO. DRAWING TITLE DRAWING NO. C&S DRG. NO.

    15 Erection Kety Diagram for S/S-2 at swbd. OSS (02-PC-302) for 415V, 3000A Non-Segregated Phase Busduct 5427PN050-DHU-E-MRS-LVS-XXX-XXX C-1410-0712-16506D

    13 Erection Kety Diagram for S/S-1 at swbd. USS (01-PC-302) for 415V, 3000A Non-Segregated Phase Busduct 5427PN050-DHU-E-MRS-LVS-XXX-XXX C-1410-0712-16506B

    14 Erection Kety Diagram for S/S-2 at swbd. OSS (02-PC-301) for 415V, 3000A Non-Segregated Phase Busduct 5427PN050-DHU-E-MRS-LVS-XXX-XXX C-1410-0712-16506C

    12 Erection Kety Diagram for S/S-1 at swbd. USS (01-PC-301) for 415V, 3000A Non-Segregated Phase Busduct 5427PN050-DHU-E-MRS-LVS-XXX-XXX C-1410-0712-16506A

    10 Supporting structure arrangement for S/S-2 at SWBD. OSS (02-PC-301) for 415V, 3000A NSPBD 5427PN050-DHU-E-MRS-LVS-XXX-XXX C-1410-0712-16504C

    11 Supporting structure arrangement for S/S-2 at SWBD. OSS (02-PC-302) for 415V, 3000A NSPBD 5427PN050-DHU-E-MRS-LVS-XXX-XXX C-1410-0712-16504D

    8 Supporting structure arrangement for S/S-1 at SWBD. USS (01-PC-301) for 415V, 3000A NSPBD 5427PN050-DHU-E-MRS-LVS-XXX-XXX C-1410-0712-16504A

    9 Supporting structure arrangement for S/S-1 at SWBD. USS (01-PC-302) for 415V, 3000A NSPBD 5427PN050-DHU-E-MRS-LVS-XXX-XXX C-1410-0712-16504B

    6 Busduct connection at Transformer end for 415V, 3000A NSPB 5427PN050-DHU-E-MRS-LVS-LAY-008 C-1410-0712-16502

    7 Busduct connection at Switchgear end for 415V, 3000A NSPB 5427PN050-DHU-E-MRS-LVS-LAY-007 C-1410-0712-16503

    4 Layout of S/S-2 at SWBD. OSS (02-PC-301) for 415V, 3000A Non-Segregated Phase Busduct 5427PN050-DHU-E-MRS-LVS-LAY-006A C-1410-0712-16501A

    5 Layout of S/S-2 at SWBD. OSS (02-PC-302) for 415V, 3000A Non-Segregated Phase Busduct 5427PN050-DHU-E-MRS-LVS-LAY-006B C-1410-0712-16501B

    2 Layout of S/S-1 at SWBD. USS (01-PC-301) for 415V, 3000A Non-Segregated Phase Busduct 5427PN050-DHU-E-MRS-LVS-LAY-005A C-1410-0712-16500A

    3 Layout of S/S-1 at SWBD. USS (01-PC-302) for 415V, 3000A Non-Segregated Phase Busduct 5427PN050-DHU-E-MRS-LVS-LAY-005B C-1410-0712-16500B

    1 General Arrangement Drawing for 415V, 3000A Non-Segregated Phase Busduct 5427PN050-DHU-E-MRS-LVS-BDU-001 C-1410-0712-16499

    Drawing List for 415V 3000A (Non-Segregated Phase Busduct)

    Non-Segregated Phase Busduct

  • ENG

    INEERIN

    G C

    ON

    SULTA

    NT:

  • ENG

    INEERIN

    G C

    ON

    SULTA

    NT:

  • YR

    BR

    NY

    B

    ENG

    INEERIN

    G C

    ON

    SULTA

    NT:

  • ENG

    INEERIN

    G C

    ON

    SULTA

    NT:

  • ENG

    INEERIN

    G C

    ON

    SULTA

    NT:

  • ENG

    INEERIN

    G C

    ON

    SULTA

    NT:

  • ENG

    INEERIN

    G C

    ON

    SULTA

    NT:

  • ITEM D

    ESCR

    IPTION

    SL.N

    O.

    SPECIFIC

    ATIO

    NSYM

    BO

    LSQ

    TY.

    ENG

    INEERIN

    G C

    ON

    SULTA

    NT:

  • ELEVATIO

    N

    NR

    YB

    RY

    B

    2 1

    IND

    OO

    RO

    UTDOO

    R

    SIDE VIEW

    GR

    AD

    EQ

    TY.M

    ATER

    IAL

    SL. NO

    .D

    ESCR

    IPTION

    BILL O

    F MA

    TERIA

    LS

    3

    ENG

    INEERIN

    G C

    ON

    SULTA

    NT:

  • ENG

    INEER

    ING

    CO

    NSU

    LTAN

    T:

  • ENG

    INEER

    ING

    CO

    NSU

    LTAN

    T:

    1 U 1 V 1 W

    224.600

    227.800

    1 U 1 V 1 W

  • ENG

    INEER

    ING

    CO

    NSU

    LTAN

    T:

  • ENG

    INEER

    ING

    CO

    NSU

    LTAN

    T:

    224.600

    227.800

    1 U 1 V 1 W

    1 U 1 V 1 W

  • ENG

    INEER

    ING

    CO

    NSU

    LTAN

    T:

  • ENG

    INEER

    ING

    CO

    NSU

    LTAN

    T:

    1 U 1 V 1 W

    224.600

    227.800

    1 U 1 V 1 W

  • ENG

    INEER

    ING

    CO

    NSU

    LTAN

    T:

  • ENG

    INEER

    ING

    CO

    NSU

    LTAN

    T:

    1 U 1 V 1 W

    1 U 1 V 1 W

    224.600

    227.800

  • ENG

    INEERIN

    G C

    ON

    SULTA

    NT:

  • ENG

    INEERIN

    G C

    ON

    SULTA

    NT:

  • ENG

    INEERIN

    G C

    ON

    SULTA

    NT:

  • ENG

    INEERIN

    G C

    ON

    SULTA

    NT:

  • ENG

    INEER

    ING

    CO

    NSU

    LTAN

    T:

  • ENG

    INEER

    ING

    CO

    NSU

    LTAN

    T:

    1 U 1 V 1 W

    227.800

    1 U 1 V 1 W

  • ENG

    INEERIN

    G C

    ON

    SULTA

    NT:

    ITEM

    NO

    .D

    ES

    CR

    IPTIO

    NISM

    B-150

    4-ISA-50X

    50X6mm

    THK

    . IN 200X200 B

    OX

    FOR

    MA

    TION

    WEILD

    ED W

    ITH BATTEN

    PLATEC

    1

    B1,B

    2,B3

    ISA-50X

    50X6mm

    THK.

    S1,S3

    ISMC

    -100C

    1

    ISA-50X

    50X6mm

    THK.

    A1

    ISA-75X

    75X8mm

    THK.

    S2

    SAY

    = 0.40 TON

    NE/BD

    NO

    . OF BD

    :- 02

  • ENG

    INEERIN

    G C

    ON

    SULTA

    NT:

    2. ALL SUPP

    OR

    TING

    STR

    UC

    TUR

    E S

    HA

    LL BE M

    S. H

    OT D

    IP GA

    LVAN

    ISED

    AS PE

    R IS:4759.

    3. ALL HA

    RD

    WA

    RE

    SH

    ALL B

    E STAINLES

    S STEEL.

    GEN

    . NO

    TES:-

    1. ALL DIM

    EN

    SIO

    NS

    AR

    E IN

    MM

    UN

    LESS O

    THE

    RW

    ISE SP

    ECIFIED

    .

    4. WH

    ENEV

    ER TH

    ER

    E IS AN

    Y MISM

    ATCH

    OF H

    OLE

    S DU

    RIN

    G JO

    ININ

    G O

    F SUPP

    OR

    T STRU

    CTU

    RE

    DU

    E TO C

    IVIL/O

    THER

    MIS

    ALIGN

    MEN

    TS,TH

    E S

    AME SH

    ALL BE W

    ELDE

    D AN

    D AP

    PLIED

    WITH

    ZINC

    SPR

    AY.

  • ENG

    INEER

    ING

    CO

    NSU

    LTAN

    T:

  • 1 U 1 V 1 W

    1 U 1 V 1 W

    ENG

    INEER

    ING

    CO

    NSU

    LTAN

    T:

  • ENG

    INEERIN

    G C

    ON

    SULTA

    NT:

    ITEM

    NO

    .D

    ES

    CR

    IPTIO

    NISM

    B-150

    4-ISA-50X

    50X6mm

    THK

    . IN 200X200 B

    OX

    FOR

    MA

    TION

    WEILD

    ED W

    ITH BATTEN

    PLATEC

    1

    B1,B

    2,B3

    ISA-50X

    50X6mm

    THK.

    S1,S3

    ISMC

    -100C

    1

    ISA-50X

    50X6mm

    THK.

    A1

    ISA-75X

    75X8mm

    THK.

    S2

    SAY

    = 0.40 TON

    NE/BD

    NO

    . OF BD

    :- 02

  • ENG

    INEERIN

    G C

    ON

    SULTA

    NT:

    2. ALL SUPP

    OR

    TING

    STR

    UC

    TUR

    E S

    HA

    LL BE M

    S. H

    OT D

    IP GA

    LVAN

    ISED

    AS PE

    R IS:4759.

    3. ALL HA

    RD

    WA

    RE

    SH

    ALL B

    E STAINLES

    S STEEL.

    GEN

    . NO

    TES:-

    1. ALL DIM

    EN

    SIO

    NS

    AR

    E IN

    MM

    UN

    LESS O

    THE

    RW

    ISE SP

    ECIFIED

    .

    4. WH

    ENEV

    ER TH

    ER

    E IS AN

    Y MISM

    ATCH

    OF H

    OLE

    S DU

    RIN

    G JO

    ININ

    G O

    F SUPP

    OR

    T STRU

    CTU

    RE

    DU

    E TO C

    IVIL/O

    THER

    MIS

    ALIGN

    MEN

    TS,TH

    E S

    AME SH

    ALL BE W

    ELDE

    D AN

    D AP

    PLIED

    WITH

    ZINC

    SPR

    AY.

  • ENG

    INEER

    ING

    CO

    NSU

    LTAN

    T:

  • ENG

    INEER

    ING

    CO

    NSU

    LTAN

    T:

    1 U 1 V 1 W

    224.450

    227.800

    1 U 1 V 1 W

  • ENG

    INEERIN

    G C

    ON

    SULTA

    NT:

    ITEM

    NO

    .D

    ES

    CR

    IPTIO

    NISM

    B-150

    4-ISA-50X

    50X6mm

    THK

    . IN 200X200 B

    OX

    FOR

    MA

    TION

    WEILD

    ED W

    ITH BATTEN

    PLATEC

    1

    B1,B

    2,B3

    ISA-50X

    50X6mm

    THK.

    S1,S3

    ISMC

    -100C

    1

    ISA-50X

    50X6mm

    THK.

    A1

    ISA-75X

    75X8mm

    THK.

    S2

    SAY

    = 0.40 TON

    NE/BD

    NO

    . OF BD

    :- 02

  • ENG

    INEERIN

    G C

    ON

    SULTA

    NT:

    2. ALL SUPP

    OR

    TING

    STR

    UC

    TUR

    E S

    HA

    LL BE M

    S. H

    OT D

    IP GA

    LVAN

    ISED

    AS PE

    R IS:4759.

    3. ALL HA

    RD

    WA

    RE

    SH

    ALL B

    E STAINLES

    S STEEL.

    GEN

    . NO

    TES:-

    1. ALL DIM

    EN

    SIO

    NS

    AR

    E IN

    MM

    UN

    LESS O

    THE

    RW

    ISE SP

    ECIFIED

    .

    4. WH

    ENEV

    ER TH

    ER

    E IS AN

    Y MISM

    ATCH

    OF H

    OLE

    S DU

    RIN

    G JO

    ININ

    G O

    F SUPP

    OR

    T STRU

    CTU

    RE

    DU

    E TO C

    IVIL/O

    THER

    MIS

    ALIGN

    MEN

    TS,TH

    E S

    AME SH

    ALL BE W

    ELDE

    D AN

    D AP

    PLIED

    WITH

    ZINC

    SPR

    AY.

  • ENG

    INEER

    ING

    CO

    NSU

    LTAN

    T:

  • ENG

    INEER

    ING

    CO

    NSU

    LTAN

    T:

    1 U 1 V 1 W

    1 U 1 V 1 W

    224.600

    227.800

  • ENG

    INEERIN

    G C

    ON

    SULTA

    NT:

    ITEM

    NO

    .D

    ES

    CR

    IPTIO

    NISM

    B-150

    4-ISA-50X

    50X6mm

    THK

    . IN 200X200 B

    OX

    FOR

    MA

    TION

    WEILD

    ED W

    ITH BATTEN

    PLATEC

    1

    B1,B

    2,B3

    ISA-50X

    50X6mm

    THK.

    S1,S3

    ISMC

    -100C

    1

    ISA-50X

    50X6mm

    THK.

    A1

    ISA-75X

    75X8mm

    THK.

    S2

    SAY

    = 0.40 TON

    NE/BD

    NO

    . OF BD

    :- 02

  • ENG

    INEERIN

    G C

    ON

    SULTA

    NT:

    2. ALL SUPP

    OR

    TING

    STR

    UC

    TUR

    E S

    HA

    LL BE M

    S. H

    OT D

    IP GA

    LVAN

    ISED

    AS PE

    R IS:4759.

    3. ALL HA

    RD

    WA

    RE

    SH

    ALL B

    E STAINLES

    S STEEL.

    GEN

    . NO

    TES:-

    1. ALL DIM

    EN

    SIO

    NS

    AR

    E IN

    MM

    UN

    LESS O

    THE

    RW

    ISE SP

    ECIFIED

    .

    4. WH

    ENEV

    ER TH

    ER

    E IS AN

    Y MISM

    ATCH

    OF H

    OLE

    S DU

    RIN

    G JO

    ININ

    G O

    F SUPP

    OR

    T STRU

    CTU

    RE

    DU

    E TO C

    IVIL/O

    THER

    MIS

    ALIGN

    MEN

    TS,TH

    E S

    AME SH

    ALL BE W

    ELDE

    D AN

    D AP

    PLIED

    WITH

    ZINC

    SPR

    AY.

  • ENG

    INEER

    ING

    CO

    NSU

    LTAN

    T:

  • ENG

    INEER

    ING

    CO

    NSU

    LTAN

    T:

    1 U 1 V 1 W

    224.600

    227.800

    1 U 1 V 1 W

  • ENG

    INEER

    ING

    CO

    NSU

    LTAN

    T:

  • ENG

    INEER

    ING

    CO

    NSU

    LTAN

    T:

    224.600

    227.800

    1 U 1 V 1 W

    1 U 1 V 1 W

  • ENG

    INEER

    ING

    CO

    NSU

    LTAN

    T:

  • ENG

    INEER

    ING

    CO

    NSU

    LTAN

    T:

    1 U 1 V 1 W

    224.600

    227.800

    1 U 1 V 1 W

  • ENG

    INEER

    ING

    CO

    NSU

    LTAN

    T:

  • ENG

    INEER

    ING

    CO

    NSU

    LTAN

    T:

    1 U 1 V 1 W

    1 U 1 V 1 W

    224.600

    227.800

    12345