Important Considerations for Specifying MV Mining Switchgear

Western Mining Electrical Association Edmonton, Canada June 13, 2008

Specifying MV Mining Switchgear

(Above 1000V and up to 38kV for Surface Mining) Key Components of Specification: Scope Applicable Standards Service Conditions Ratings Construction Tests Quality Assurance System

Specifying MV Mining Switchgear

Scope
Scope of work Define what is required Example: This specification defines requirements of one (1) 69kV-25kV, 60Hz, 15 MVA mine-duty skid mounted portable substation with primary structure, transformer, neutral grounding resistor and secondary switchgear, close coupled to transformer.

Applicable Standards
(For illustration only)
IEE Std C37.20.3-2001 Metal-Enclosed Interrupter Switchgear IEEE Std C37.06-2000 AC HV Circuit breakers IEEE Std C37.22 MV Switches used in indoor Metal-Enclosed Switchgear NFPA 70E-2000, Electrical Safety Requirements for Employee Workplace IEEE Std 1584-2002, IEEE Guide for performing Arc-Flash Hazard Calculations NEC, National Electric Code

Types of Switchgear Assemblies Defined by IEEE Standards

SWITCHGEAR ASSEMBLIES METAL-ENCLOSED POWER SWITCHGEAR LOW-VOLTAGE POWER CIRCUIT BREAKER (LV) C37.20.1 METAL-CLAD (MC) C37.20.2 METAL-ENCLOSED INTERRUPTER (MEI) C37.20.3 GUIDE FOR TESTING MV ME SWITCHGEAR FOR INTERNAL ARCING FAULTS C37.20.7-2001 METAL-ENCLOSED BUS C37.23 NON-SEGREGATED PHASE SEGREGATED PHASE ISOLATED PHASE REQUIREMENTS AND GUIDE FOR CALCULATING LOSSES CONTROL SWITCHBOARDS C37.21 VERTICAL (OPEN OR ENCLOSED) DUAL DUPLEX CONTROL DESK BENCHBOARD DUPLEX BENCHBOARD FIXED RACK CABINET SWING RACK CABINET

Specifying MV Mining Switchgear

Service Conditions
Usual Service Conditions The equipment shall be designed for the following service conditions: 1. The temperature of the cooling air surrounding the enclosure of the switchgear is within the limits of -30 C and +40 C 2. The altitude of the installation does not exceed 1000 m (3300 ft) 3. The effect of solar radiation is not significant

Specifying MV Mining Switchgear

Unusual Service Conditions
Or you may list: 1. The equipment shall be suitable to operate within the limits of -30 C and +50 C (require either derating or select next higher ampacity rating) 2. The altitude of the installation does not exceed 1500 m (5000 ft), (require either de-rating or use higher insulation level 3. The effect of solar radiation shall be considered per IEEE Std C37.24

Specifying MV Mining Switchgear Load current-carrying capabilities at various ambients

552A 1104A

Specifying MV Mining Switchgear Altitude Correction Factors

Switchgear that depends on air for an insulating and cooling medium will have a higher temperature rise and a lower dielectric withstand capability when operated at higher altitudes The following Table shows historical altitude correction factors for dielectric withstand voltage and continuous current Specifier may refer to Annex B of IEEE PC37.100.1 for additional guidance

Specifying MV Mining Switchgear Altitude Correction Factors

Effect of Solar Radiation is Normally Insignificant Monthly Normal Max Temp in US & Canada See IEEE Std C37.24-2003 for Ref Station Phoenix Las Vegas Sheridan Evansville Fairbanks Edmonton June
39.7 C/103.5 F 37.9C/100.2F 24.9C/76.8F 30.1C/86.2F 21.2C/70.2F 20.9C/69.6F

July
41.1 C/106 F 41.1C/106F 30.1C/86.2F 31.7C/89F 22.4C/72.3F 22.5C/72.5F

August
39.8 C/103.6 F 39.6C/103.3F 29.6C/85.3F 30.7C/87.3F 19.1C/66.4F 21.8C/71.2F

Temperature rise of about 15 C may be expected on the conducting parts due to solar radiation

Specifying MV Mining Switchgear

Ratings
Ratings of Switchgear Designations of Operating Limits under Specified Conditions Rated maximum voltage Rated power frequency Rated insulation levels Rated continuous current Rated momentary withstand current Rated short-time withstand current

1. 2. 3. 4. 5. 6.

Specifying MV Mining Switchgear

Example 25kV Dual VCB House w/o NGR
Ratings of Switchgear 1. Rated maximum voltage = 27kV rms 2. Rated power frequency = 60Hz 3. Rated insulation levels: Power frequency withstand
voltage = 60kV rms; BIL = 125kV peak

4. Rated continuous current = 1200A 5. Rated momentary withstand current = 43kA peak(10 Cy) 6. Rated short-time withstand current = 16kA (2 s) Bkrs have SC interrupting rating, switches do not Switches do have fault close rating

Specifying MV Mining Switchgear

Example Neutral Grounding Resistor
1. 2. 3. 4. 5. 6. 7. Ratings of NGR 23.9kV L-L, 13.8kV L-N, 60 Hz Resistance @ 25 C = 552.0 Ohm Current = 25A Duty/Max Temperature rise = Extended/610 C Finish = Mill galvanized Enclosure type = Outdoor IEEE Std 32-1972, reaffirmed 1990

Specifying MV Mining Switchgear

Neutral Ground Monitoring if applicable Specify 1. Neutral ground monitoring device 2. Sensing resistor 3. Current transformer

Specifying MV Mining Switchgear Rating of Simple 25kV Junction box

Specifying MV Mining Switchgear

25kV Junction box
Ratings of Switchgear 1. Rated maximum voltage = 27kV rms 2. Rated power frequency = 60Hz 3. Rated insulation levels: Power frequency withstand
voltage = 60kV rms; BIL = 125kV peak

4. Rated continuous current = 600A 5. Rated momentary withstand current = ??kA peak(10 Cy) 6. Rated short-time withstand current = ??A (2 s)

Specifying MV Mining Switchgear

Associated Major Components
Ratings of major components should also be listed in specification Vacuum circuit breakers Disconnect switches (specify load-break or non load-break) Instrument transformers (CTs, PTs & CPTs) Lighting arresters (MCOV for grounded or ungrounded system) Ground monitor Metering, controls, relays and ground monitors Power transformers and primary structures for portable substations

1. 2. 3. 4. 5. 6. 7.

Specifying MV Mining Switchgear

Construction Considerations for Rugged Mine Duty Switchgear
Skid (shall be fabricated using the following structural members) Wide flange I-beams for cross members Heavy duty structural steel channels for runners 18-26 Wide runners with 3/8 steel plates on bottom Thick steel deck and belly plates -1 Thick steel wear plates under runners 1 X 10 X 30 steel towing eyes with 3 eye Towing eyes at 45 degree angle to facilitate lifting with slings 1 Diameter steel J-hooks for tying off the cables

Specifying MV Mining Switchgear Skid for Portable Substation (Partial view)

Specifying MV Mining Switchgear Skid for Portable Substation

Specifying MV Mining Switchgear Skid for Portable Substation

Specifying MV Mining Switchgear

Construction Considerations for Rugged Mine Duty Switchgear
Enclosure (shall be fabricated with) 11 Gauge steel with seam welded construction Stainless steel hinges and door hardware Galvanized steel slide-bolt latches with provisions for padlocking Double flange door construction with drip shield Nema 3-R construction with door stops and gaskets Viewing windows for disconnect switches Adequate cable termination height 3/8 Steel plates for blast protection of transformers

Specifying MV Mining Switchgear

Construction Considerations for Mine Duty Switchgear
Enclosure Finishes After the enclosure fabrication all welds and hard to reach areas shall be cleaned with steel wire brush and power grinder to remove any corrosion, weld splatter and scale All enclosures shall be cleaned with high pressure phosphatizing solution to clean and etch the surfaces Enclosure shall be painted with a minimum of 1.5-2.0 mil high-solids primer and 2.0-3.0 mil acrylic enamel top coat Electronic paint gauge may be used to assure uniform quality finish Exterior paint shall withstand 2000 hours of exposure to a 5% salt spray

Steel Fabrication
Welds are cleaned with a steel wire brush Power grinder is used to remove any corrosion, scale and weld splatter

Steel Fabrication
High pressure cleaning with phosphatizing solution, rinsing and air drying of sub-assemblies and assemblies

Construction Two-Coat Paint System

Primer: Alkyd high-solids universal primer Finish Coat: Acrylic enamel, high-solids semi-gloss finish 2000 Hrs of salt spray withstand, resistant to chalking, peeling, and UVR

Specifying MV Mining Switchgear 38kV Switch and Fuse Enclosure for Portable Sub

Specifying MV Mining Switchgear Blast Protection of transformers

11 Ga Seam welded construction

3/8 Steel Plates

Optional top lifting structure for crane handling

Specifying MV Mining Switchgear

Wiring
Control and secondary wiring Wiring shall be rated for 600V, and 90 C, and shall be flame-retardant. Wire shall be type SIS as listed in the NEC. Wiring across a hinge shall be flexible to withstand repeated door movement without sustaining damage to wire strands or insulation Wire size shall be suitable for the maximum steady-state load Wire shall be No. 14 AWG and larger

Insulation Coordination When Cables are ran through neutral CT

CTs are properly spaced and air gaps are sealed with RTV to eliminate corona

Specifying MV Mining Switchgear

Production Tests
Production tests made for quality control shall be performed to assure that product meets the design specifications and applicable standards Power frequency (60Hz) dielectric tests Mechanical operation tests (Functioning of operating mechanisms, interlocks, door locks etc) Grounding of instrument transformer cases (Metal case design only) Control wiring continuity check (Operational check) Polarity verification (To ensure correct connections between instrument transformers and meters) Request test data for power transformer if applicable

1. 2. 3. 4. 5. 6.

Final Inspection & Production Tests

Specifying MV Mining Switchgear Quality Assurance

Vendor shall be certified to ISO-9001 Quality Management System Vendor shall provide MSHA certified field service technicians when required

MSHA Certified technicians

Questions?

Thank you