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SPECIFICATION
( REVISION RECORD )

SPECIFICATION No
SOPC
3750-200-510-019
SPECIFICATION FOR

NEW ASPHALET UNIT PROJECT

LOW VOLTAGE VARIABLE SPEED DRIVE SYSTEM

TillS PAGE RECORDS THE REVISIONS OF TillS SPECIFICATION SINCE ITS ADOPTION. THE NATURE OF
EACH REVISION IS BRIEFLY NOTED UNDER REMARKS. FOR CONVENIENCE, EACH REVISION IS BRIEFLY
DESCRIBED IN THE NEXT PAGE.

REV DATE BY APPROVAL PAGES REMARKS

0 June 03, 2015 A.D. , M,..SI': 4 15 ISSUED FOR APPROVAL

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N TillS SPECIFICATION IS THE PROPERTY OF ENPPI. IT IS FURNISHED TO ESTABLISH ENPPI REQUIREMENTS
ON A PARTICULAR PROJECT AND SOLELY FOR THAT PURPOSE. TillS SPECIFICATION IS NOT INTENDED
,..... FOR GENERAL CIRCULATION, AND IT SHALL NOT BE REPRODUCED OR DISTRIBUTED WITHOUT ENPPI
WRITTEN PERMISSION.
SPECIFICATION PAGE 2 OF 15

SOPC 3750-200-510-019

SUEZ, EGYPT REV.O

REVISION DESCRIPTION AND DETAIL


SPECIFICATION PAGE 3 OF 15

SOPC 3750-200-510-019

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1.0 4

2.0 REFERENCE DOCUMENTS 4

3.0 ORDER OF PRECEDENCE 5

4.0 DEFINITIONS 5

5.0 ABBREVIATIONS 6

6.0 DESIGN, CONSTRUCTION AND TECHNICAL REQUIREMENTS 6

7.0 PAINTING 13

8.0 PREPARATION FOR SHIPMENT 14

9.0 NAMEPLATES, EQUIPMENT LABELS AND INSTRUCTIONS 14

10.0 INSPECTION AND TESTING 15


SPECIFICATION PAGE 4 OF 15

SOPC 3750-200-510-019

EGYPT REV.O

This specification defines the technical requirements for the design, manufacturing,
painting, inspection, testing and shipping of low voltage variable speed drive system (VSD).

The reference documents listed below form an integral part of this Specification.

2.1 CODES & STANDARDS

IEC 60034-25 Rotating electrical machines- A.C electrical machines used in


power drive systems - application guide
IEC 60044-7 Instrument transformers - Electronic voltage transformers
IEC 60044-8 Instrument transformers - Electronic current transformers
IEC 60146 Semiconductor converters
IEC 60529 Degrees of protection provided by enclosures (IP Code)
IEC 60947 Low-voltage switchgear and control gear
IEC 61000 Electromagnetic compatibility (EMC)
IEC 61800 Adjustable speed electrical power drive systems
IEC 61800-1 Adjustable speed electrical power drive systems - General
requirements- Rating specifications for low-voltage adjustable speed
D.C power drive systems
IEC 61800-2 Adjustable speed electrical power drive systems- General
requirements- Rating specifications for low-voltage adjustable speed
A.C power drive systems
IEC 61800-3 Adjustable speed electrical power drive systems - EMC
requirements and specific test methods
IEC 61850 Communication networks and systems for power utility automation
IEC 61869 Instrument transformers
IEC 62262 Degrees of protection provided by enclosures for electrical
equipment against external mechanical impacts (IK code)

Unless otherwise stipulated, the applicable version of these documents, including relevant
appendices and supplements, is the latest revision published at the EFFECTIVE DATE of the
CONTRACT.

Codes & Standards equivalent to those referenced herein shall not be substituted without written
approval from the Customer.
SPECIFICATION PAGE 5 OF 15

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event conflicts among referenced documents above, the order of precedence shall be
as follows:

a) The Equipment Data Sheets(s).


b) The referenced Codes & Standards.

Where this specification states no overriding requirements, the referenced Codes and Standards
shall apply in full.

Any conflicts between this specification and other applicable Specification, Codes and Standards
or local applicable laws shall be brought to the attention of the Customer for resolution.

4.0 DEFINITIONS

COMPANY The Organization which initiate the Project and pay for it.
CUSTOMER The Organization or person that receives a product.
CUSTOMER The Organization or Person duly appointed by the CUSTOMER or
REPRESENTATIVE COMPANY to act as its representative(s) to supervise and control
the job.
INSPECTION The Conformity evaluation by observation and judgment
accompanied as appropriate by measurement, testing or gauging.
INSPECTOR The CUSTOMER or COMPANY representative(s), (as applicable),
or member(s) from an Inspection Agency duly appointed by the
CUSTOMER or COMPANY to act as its representative(s) for the
purpose of the contract.
MANUFACTURER The party selected by the CUSTOMER or the SUPPLIER (as
applicable) as the Manufacturer of the said materials.
SUPPLIER The Organization which provide the service and I or supply
equipment to perform the duties specified by the CUSTOMER.
SPECIFICATION PAGE 6 OF 15

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Electromagnetic Compatibility
ENMCS Electrical Networks Monitoring and Control System
IEC International Electrotechnical Commission
IK International numeric classification for the degrees of protection
provided by enclosures for electrical equipment against external
mechanical impacts.
IP Ingress Protection
PVC Poly Vinyl Chloride
RFI Radiated Electromagnetic Field
XLPE Cross Linked Poly Ethylene

6.0 DESIGN, CONSTRUCTION AND TECHNICAL REQUIREMENTS

6.1 GENERAL REQUIREMENTS

6.1.1 The voltage and frequency variations shall be limited to the following values:

a. Voltage 10%.
b. Frequency 5 %.

6.1.2 Performance of the VSD shall be in complete compliance with the requirements of the
driven equipment given by the driven equipment Supplier. The VSD shall be suitable for
the load characteristics and the operational duty of the driven equipment.

6.1.3 The VSD shall be designed for use with any squirrel cage induction motors having a
service factor of 1.15

6.1.4 The VSD Supplier shall perform all necessary analysis for operation of the induction motor
when powered by the VSD to assure that the motor shall operate in a stable manner
without undue excessive power loss, heating, vibration or noise and with adequate torque
margin for the specified acceleration requirements.

6.1.5 Space heater within enclosure shall be provided, unless otherwise specified in the data
sheet.

6.1.6 All cables entering the VSD from bottom, unless otherwise specified in the data sheet.

6.2 CONVERTER TRANSFORMER

6.2.1 Converter transformer shall be dry-type, unless otherwise specified in the data sheet.

6.2.2 The converter transformer shall be housed/located inside the VSD cubical inside the
substation with the international protection shall be IP21 as a minimum, unless otherwise
specified in the data sheet.
SPECIFICATION PAGE 7 OF 15

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6.2.3 converter transformer shall be suitable operation with the non-pure sinusoidal
current wave shapes (sinusoidal with harmonics) and DC components under and
abnormal conditions (e.g. short circuits) of the VSD without exceeding its temperature or
other limits under the conditions this specification.

6.2.4 Two winding transformer shall be provided for the VSD with 6-pulse rectifier, on the other
hand, three winding transformer shall be provided for the VSD with 12-pulse rectifier.

6.2.5 Input transformer impedances shall be selected to limit the initial fault current to a safe
value for converter power electronic elements.

6.2.6 An overload of the transformer shall trip the VSD and give an indicating alarm on the
converter.

6.3 CONVERTER

6.3.1 In general, the converter shall conform to the requirements ofiEC 60146.

6.3.2 The converter cabinet shall be installed indoor, self-supporting and suitable for floor/wall
mounting and international protection of IP31, except heat exchanger openings, which may
be IP21.

6.3.3 The Supplier shall provide the heat load of indoor equipment (transformer and converter)
with his quotation.

6.3.4 In general, each converter should comprise the following main components as a minimum;

a. Isolation switch (lockable in "off' position).


b. Rectifier.
c. DC link. (Capacitor bank)
d. Inverter. (Pulse width modulation PWM)

6.3.5 Inverters shall be voltage source inverters. The inverters shall be PWM (pulse width
modulated) and shall utilize IGBT (insulated gate bipolar transistor), where the output
voltage and frequency shall be controlled together (V/F=constant). The motor supply
frequency (motor speed) shall be controlled through the inverters.
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S 6.4 SYSTEM CONTROL, PROTECTION, AND ALARM EQUIPMENT
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6.4.1 SYSTEM CONTROL

6.4.1.1 The VSD shall be controlled by fully digital microprocessor-based system.


6.4.1.2Communication interfaces with other devices, ENMCS ... etc., shall modbus, unless
otherwise specified in the data sheets.
SPECIFICATION PAGE 8 OF 15

SOPC 3750-200-510-019

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system shall be suitable for local and remote control shall have a readout
for the status indication and set values.
6.4.1 diagnostic protection system protect
including motor protection.

6.4.2 The frequency converter shall be controlled by the following signals, unless otherwise
specified in the data sheet:

a. 4-20 rnA reference signal (supplied by Customer).


b. 4 rnA shall refer to minimum operating speed. If this signal is lost, the drive shall
decelerate to minimum operating speed.
c. Ready to start signal (interposing "on" signal) external voltage free contact will be
given if the VSD is allowed to be started.
d. Stop signal (interposing "off" signal) external potential free contact is given by an
emergency condition of the driven equipment or the process.
e. Remote stop signal.
f. The stop signal given from the stop push button located near the motor shall trip the
contactor/motor circuit breaker.
6.4.2.2The system shall be equipped with "data logging" facility. The design shall be based
on the principle that only the essential data logging are installed in order to simplify the
circuiting and reduce the not needed data logging. The Supplier shall submit his
standard data logging scheme.
6.4.2.3For additional motor data logging, refer to the one line diagram unless otherwise
specified.
6.4.2.4The control system shall be immune from spikes and voltage distortion due to
operational and/or fault conditions within the VSD.
6.4.2.5When required/specified in data sheet or material requisition, the drive shall
incorporate a manually selectable, auto restart feature which functions as follows:
a. With the feature selected, if the voltage remains at the 70% to 90% level for longer
than 12 cycles, or if the voltage drops below 70% nominal, an automatic restart
sequence shall be initiated. It shall not be necessary that the motor coast to a
complete stop before the motor is reaccelerated. The restart sequence shall function
in the following manner:
- If voltage is restored to at least 90% within an adjustable time of 1 to 3 seconds,
the drive system will automatically reaccelerate.
- If voltage is not restored within the above time period, the drive will shut down
and require a manual reset to restart.
b. With the feature not selected, if the voltage remains at the 70% to 90% level for
longer than 12 cycles, or if the voltage drops below 70% nominal, the drive will shut
down and require a manual reset to restart.
SPECIFICATION PAGE 9 OF 15

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EGYPT REV.O

6.4.3 PROTECTION

6.4.3.1 The design shall be based on the principle that only the essential protection
functions are installed order to simplify the circuiting and reduce risk of
unnecessary trips. The Supplier shall submit his standard protection scheme.
6.4.3.2For additional functions of motor protection devices, refer to the one line diagram
unless otherwise specified.

6.4.4 ALARMS

6.4.4.1Alarms and faults shall be annunciated on the front panel.


6.4.4.2Each alarm or shutdown shall be associated by hom signal and flashing lamps.
6.4.4.3The following alarms shall be monitored as a minimum:
a. Input over current protection
b. Input under/over Voltage protection.
c. Motor over current protection.
d. Motor overload, locked rotor, windings over temperature, and bearings over
temperature protection.
e. Motor over/under speed protection.
f. Loss of reference signal.
g. Fan failure.
6.4.4.4Adjustable time delays shall be provided for each alarm function to prevent spurious
alarm signals being generated during transitory conditions.
6.4.4.5Alarm signals shall be combined to provide two "common alarm" signals wired to a
terminal strip for remote indication.

6.5 MEASUREMENTS

Measurements shall be provided as minimum as follows:

6.5.1 Input voltage/current/frequency.


6.5.2 Output voltage/current/frequency.
6.5.3 Output torque.
6.5.4 Output power.
6.5.5 Speed.
SPECIFICATION PAGE 10 OF 15

SOPC 3750-200-510-019

EGYPT REV.O

LIGHTS

6.6.1 For each VSD,

a. Mains "ON" Red light.


Mains "failure" Yellow light.
c. Converter "ON/OFF" Green/Red lights.
d. Motor "Running" Red light.
e. Ready to start.

6.6.2 All indications shall be mounted on the VSD cubicle front.

6.6.3 Lamps shall be accessible from the front of the cubicle to facilitate lamp replacement.

6.6.4 Indicating lights by means of light-emitting diodes (LED's) are acceptable while the use of
filament lamps is not accepted.

6.6.5 Lights shall be provided with lamp test facilities.

6.7 PUSH BUTTONS AND SWITCHES

6.7.1 The controller shall have start and stop push-buttons to start the unit or to stop in addition
to the possibility to start or stop the unit via the pad start/stop function.

6.7.2 The controller shall have an emergency stop button, to shut the controller down instantly
whenever needed. This button function supersedes any other command.

6.7.3 The controller shall have local-off-remote switches to define the operation either from the
door mounted device or key pad or via a remote control signal. In the off position, the
operation cannot be started.

6.8 COOLING REQUIREMENTS

6.8.1 Cooling method shall conform to IEC 60146 and as specified on the data sheet. Cooling air
openings shall only be located on front or on top of the panels. Forced ventilation shall
include the necessary air filters, fans and ducting.

6.8.2 Where forced ventilation is provided, failure of a single fan unit shall not cause the
converter to shutdown at full load. Transfer to redundant fan shall be automatically
initiated upon failure of primary fan. An alarm shall be given in the event of a fan failure.
Replacement of faulty fan can be achieved without converter shutdown.

6.8.3 The control scheme shall automatically alternate the operation of the primary and
redundant fans to equalize wear.
SPECIFICATION PAGE 11 OF 15

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EGYPT REV.O

6.8.4 short circuit.

6.9.1 Under normal operating conditions, the AC power supplied to the VSD shall be rectified
by the rectifier circuit, converted to DC voltage. The DC voltage shall be converted back to
AC power with controlled voltage and frequency and delivered to the motor terminals.

6.9.2 The VSD shall be responsible for the following functions:

6. 9 .2.1 Variation of motor speed from zero to the maximum allowable mechanical speed.
6.9.2.2Provision of motor torque levels over the overall speed range suitable for the driven
equipment.
6.9.2.3Provide controlled and adjustable motor acceleration and deceleration suitable for
the driven equipment.
6.9.2.4Reduction of motor starting current to values suitable for electrical system
satisfactory operation.
6.9.2.5Perform all protection functions for both the driver and the motor.

6.9.3 The VSD shall be capable of developing at least the torques as per the following table:

During starting & 150% maximum rated torque for 10


restarting seconds.
CONSTANT
After starting & restarting 120% maximum rated torque for 60
TORQUE
and during reacceleration seconds.
DRIVES
The maximum torques according to
Continuously
the maximum rated torque curve.
During starting & 120% maximum rated torque for 10
restarting seconds.
OTHER
After starting & restarting 110% maximum rated torque for 60
TORQUE
and during reacceleration seconds.
DRIVES
The maximum torques according to
Continuously
the maximum rated torque curve.

6.9.4 The VSD shall meet above torque requirements at any line voltage between 95% and 110%
of the nominal line voltage. For line voltages between 90% and 95% of the nominal line
voltage the same torque requirements apply. however, the maximum operating time under
these conditions is limited to 3 minutes, and a lower speed than the corresponding required
speed is allowed.

6.9.5 The Supplier of the VSD shall obtain from the driven equipment Supplier all relevant data
such as the exact torque speed characteristics of the driven equipment for the design of the
VSD.
SPECIFICATION PAGE 12 OF 15

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EGYPT REV.O

HARMONIC

6.10.1 The total harmonic distortion THD at point of common coupling (PCC) with the
network shall not exceed 5% for current at motor rated speed. These criteria shall be met
with all network configurations of the power system. VSD Supplier shall run computer
simulation of the system to simulate an estimate of the harmonic levels produces by the
VSD and provide it to Customer for review and approval. For exact values requested refer
to data sheets.

6.10.2 When harmonic filtering is required, the Supplier shall take into consideration the power
supply network configuration to avoid resonance frequencies under foreseen possible
operating conditions.

6.10.3 Harmonic analysis calculation shall be submitted during detailed engineering indicating the
values of Total Harmonic Distortion (THD) with and without the installation of harmonic
filter for customer review and approval.

6.11 WIRING
6.11.1 All internal wiring shall be flexible standard copper conductor, PVC or XLPE insulated,
60011000 V, flame retardant.

6.11.2 Minimum wire size for control wmng shall be 1.5 mrn2 and for power and current
transformer wiring 2.5 mm2

6.11.3 As far as practicable, signal conductors shall be segregated from power wiring and AC
wiring shall be segregated from DC wiring.

6.11.4 Each conductor and its terminations are to be identified and marked with numbered and/or
lettered ferrules in accordance with the related wiring diagram.

6.12 CABLE TERMINATIONS

6.12.1 All power cables shall have compression type lug connections.

6.12.2 All power connections shall be bus bars connection provided with stud type terminals
complete with nut and locknuts.

6.12.3 All terminal blocks shall be shrouded or provided with transparent covers.

6.12.4 Cable gland plates shall be readily removable for the drilling and fitting of glands. Gland
plates shall be made from metallic non-magnetic materials.

6.12.5 Power connections shall be of the disconnect able cable termination system. Terminations
system shall be of sufficient size to adequately terminate the specified cables/conductor
type or size.
SPECIFICATION PAGE 13 OF 15
SOPC 3750-200-510-019

SUEZ, EGYPT REV.O

The sound pressure at one meter distance from the VSD measured under all possible
loading conditions shall not exceed 85 dB(A).

6.14.1 High conductivity copper earthing bars shall be extended to the full width of the assembly.
The earthing bar shall be of adequate cross-sectional area and mechanical strength to allow
convenient connection of all cable earthing connectors and an external earthing cable sized
95 mm2 minimum.

6.14.2 All metallic, non-current carrying parts shall be bonded together and to the copper earth bar.

6.14.3 All gland plates shall be provided with earth straps to provide a positive connection
between the gland plate and cubicle earth.

6.15 IMMUNITY

6.15.1 ELECTRICAL IMMUNITY

Equipment shall be able to generally withstand the impact of the imposed electrical tests as
defined in referenced IEC.

6.15.2 DISTURBANCE IMMUNITY

The entire system shall be suitably screened to optimize electromagnetic compatibility (EMC).
The whole equipment shall be type tested in accordance with IEC 61000-4, level 3 - typical
industrial environments.
The Supplier shall provide type test certificates from a recognized testing authority to verify that
the whole equipment is effectively screened against EMC in line with the applicable IEC
standards.

7.0 PAINTING

7.1 The equipment shall be thoroughly cleaned of scale, sand, rust and grease.

7.2 The equipment shall have a surface finish which complies with the Supplier's standard for
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enhanced protection against corrosion. The paint system applied shall provide adequate
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g 7.3 The equipment shall effectively protect against the effects of corrosion.
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7.4 The Supplier shall provide with the quotation for the Customer's approval, details of the all
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surface treatments, galvanizing, base, intermediate and final painting systems, including the
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g minimum thickness of each application, and an assurance of suitability to meet the specified
N requirements.
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SPECIFICATION PAGE 140F 15
SOPC 3750-200-510-019

SUEZ, EGYPT REV.O

The external finish colour shall be manufacturer standard otherwise specified on sheet.

8.1 The equipment shall be thoroughly dried out at the Supplier's workshop.

8.2 The Supplier shall take all measures to avoid any risk of damage or deterioration during
shipping. When shipment is by sea, the equipment must be adequately protected against knock
and salt-water spray ... etc.

8.3 The equipment shall be suitable for standing for at least one year prior to commissioning. The
equipment storage shall be outdoor, therefore, all cable entry holes shall be suitably sealed
plugged so as to prevent the ingress of water.

8.4 Compound, in suitable containers, shall be supplied by the Supplier if the cable boxes are to be
compound filled on site.

9.0 NAMEPLATES, EQUIPMENT LABELS AND INSTRUCTIONS

9.1 Nameplates shall be provided to identify the VSD. These shall be attached to the external
surfaces of the assembly.

9.2 Nameplates shall also be provided to identify, indicating lights, instruments, control switches,
circuit breakers, the internal power, control and protective components and cards, etc.

9.3 Compartments which contain accessible permanently live terminals shall be provided with
warning signs, advising personnel of this fact.

9.4 Nameplates shall be made of corrosion resistant material with engraved black letters on white
background.

9.5 Nameplates shall be attached using a minimum of two stainless steel screws per plate. Adhesive
type nameplates are not acceptable.

9.6 Inscriptions shall be in the English language.

9.7 The following information in addition to standard markings shall be added:

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9.7.1.1 Manufacturer's name.
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c 9.7.1.2 Type designation, and serial number
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9.7.1.4 Purchase order number
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g 9.7.1.6 Number of input phases, and wires
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SPECIFICATION PAGE 15 OF 15

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EGYPT REV.O

9.7.1.8 of output phases, and wires


9.7.1.9 Rated output voltage, current, and frequency
1. Range of output frequency
9.7.1.11 Cooling method
9.7.1. Mechanical degree of protection (IP code)

10.0 INSPECTION AND TESTING

10.1 Purchaser's minimum quality surveillance (PMQS) is the Customer document that combines the
minimum requirements relevant to verifications, inspections and tests.

10.2 Purchaser's minimum quality surveillance sets up Customer inspection activities plan and shows
for each check, inspection or test the following points:

a. Type of intervention (Review, Hold Point, Witness)


b. Required certification
c. Possible presence of Inspection Authorities or Third Party Inspection Agency

10.3 Supplier shall prepare an overall inspection document that shall include all the documentation
pertaining to the supply, (as drawings, mechanical calculations, material certificates, non-
destructive examination certificates, calibration test certificates, etc.) and shall be always at
disposal of the inspectors who will check, stamp and sign the documents as soon as available
after each inspection and test.

10.4 All tests and inspections including all certificates shall be at Supplier's charge. The Supplier at
no cost for the Customer shall do any work necessary to put the supply in conformity with the
specifications.

10.5 A third party inspection agency can be named by the Customer I Company and entitled to
witness the inspections and tests on behalf of them.

10.6 The Supplier shall notify the Customer in writing three weeks in advance with the date and place
where the materials and I or equipment will be available for inspection and test.

10.7 Supplier shall provide at no cost all necessary assistance, instruments, equipment and energy to
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10.8 Customer reserve the right to witness the final tests by means of their inspectors and to inspect
g all materials and/or equipment during the working phase in the Supplier's and Sub-Supplier's
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