PowerVac 5-15kV Metal-Clad Switchgear Guide Specification



1. General

1. The intent of this specification is to have the manufacturer furnish the equipment and material specified herein complete and operable.

2. All standard accessories to the equipment specified shall be supplied even if not specifically mentioned in this specification.

3. Material used in the fabrication of the specified equipment shall be new, unused, and of the highest quality available.

2. Scope

1. Work Included

1. Furnish metal-clad switchgear as detailed in Sections 3.0 through 13.0 of these specifications. Any drawings or data sheets attached to the inquiry shall be considered part of this specification. The equipment shall be complete and operable.

2. Provide production tests and inspections as detailed in Section 14.0 of this specification.

3. To reasonably prevent the possibility of shipping damage, the manufacturer shall prepare the equipment for transportation to the jobsite and monitor the load out of this material.

4. It shall be the responsibility of the manufacturer to furnish all material, connections, splices, links, special tools, and information required to completely reassemble the switchgear in the field or to facilitate the installation of the switchgear when performed by an electrical contractor.

5. Guarantee the performance of the switchgear during a reasonable warranty period. This warranty shall, at a minimum, cover the equipment for eighteen (18) months from time of shipment or twelve (12) months from date of energization whichever occurs first.

6. Supply all drawings, documentation, and information detailed in Section 15.0.

2. Work Not Included

1. Field installation of switchgear, unless otherwise specified.

2. Connection of incoming cables or bus.

3. Connection of outgoing branch feeder cables or bus.

4. Connection of external control cables or wiring.

3. Applicable Codes and Standards

1. The applicable codes and standards listed below should be considered as part of this specification. The latest revision in effect at time of inquiry shall apply for all standards referenced.

1. National Electrical Manufacturers Association (NEMA)

1. NEMA SG-2

2. NEMA SG-4

3. NEMA SG-5

2. Institute of Electrical and Electronic Engineers (IEEE)

3. National Electric Code (NEC)

4. American National Standards Institute, Inc. (ANSI)

1. ANSI C37.04

2. ANSI C37.06

3. ANSI C37.09

4. ANSI C37.20.2

5. ANSI C57.13

2. Furnish Power/Vac medium-voltage metal-clad switchgear with UL or CSA label as indicated on the drawings.

3. It shall be the manufacturer's responsibility to be knowledgeable of these standards and codes.

4. Service and Environmental Conditions

1. Switchgear shall be located in well ventilated areas, away from hazardous materials; and free from excess humidity, dust and dirt.

2. Unless otherwise specified this equipment is intended for use in ambient temperatures that do not exceed a maximum of 40°C (104°F) or a minimum of -30°C (-22°F).

3. This equipment is intended for use in an area where the elevation is less than 3300 feet above sea level. Above 3300 feet a de-rating factor as prescribed by ANSI standards will apply.

4. Switchgear shall be qualified for use in seismic areas as follows:

1. High seismic loading as defined in IEEE 693-2005 with a 1.4 amplification factor.

2. IBC-2006, Sds=1.10g, Ss = 165%, Ip = 1.5 for all z/h greater than 0 and Sds = 1.75g, Ss = 262%, Ip = 1.5 for z/h equal to 0 in accordance with ICC-ES-AC156.

3. Seismic compliance shall be qualified only through shake table testing. Compliance by calculation is not acceptable.

5. Delivery, Storage and Handling

1 Deliver, store, protect, and handle products in accordance with recommended practices listed in manufacturer's Installation and Maintenance manuals to avoid damaging equipment, installed devices, and finish. Lift only by installed lifting eyes.

2 Deliver each medium voltage metal clad switchgear section in individual shipping splits for ease of handling. Each section shall be mounted on shipping skids and wrapped for protection.

3 Inspect and report concealed damage to carrier within specified time.

4 Store in a clean, dry space. Maintain factory protection or cover with heavy canvas or plastic to keep out dirt, water, construction debris, and traffic. Heat enclosures to prevent condensation.

6. Basic Construction

1. The equipment supplied shall be [indoor/outdoor/protected aisle/common aisle] metal-clad switchgear intended for use on [2.4/4.16/4.8/6.9/7.2/12.47/13.8]kV, 3-phase [3/4] wire, [grounded/ungrounded], [50Hz/60Hz] system.

2. Protected Aisle Enclosures

1 Outdoor protected aisle metal clad switchgear shall be enclosed in a weatherproof enclosure. An aisle space measuring a minimum of 75 inches from the exterior front to the breaker covers shall be provided. Provide 36 inch wide aisle space extension to the left of the switchgear front and a 12 inch wide aisle space extension to the right of the switchgear front. The aisle is shipped “knocked down” for job assembly at the jobsite.

2 Include suitable weatherproof aisle access doors with provision for padlocking. Interior of access doors shall be provided with panic style hardware.

3 Provide protected ventilation openings as required; interior lighting, utility outlets with protective devices; and equipment heaters with protective devices. Heaters are to remain energized with no switch or thermostat provided. In each unit, major primary circuit parts (breaker, buses, transformers) shall be completely enclosed by grounded metal barriers, including a front barrier as part of the circuit breaker.]

3. The construction shall be self-supporting and free standing. All metal work shall be free from burrs and sharp edges.

4. The equipment shall be suitable for service, and constructed with an enclosure, as specified on the drawings or data sheets.

5. Switchgear shall consist of breaker and auxiliary units, as indicated in drawings, assembled to form a rigid, self-supporting, metal-clad structure. The structure shall include [front doors with provision for padlocking] [rear doors with provision for padlocking] [front and rear doors with provision for padlocking] and protected ventilation openings as required.

6. The switchgear lineup shall be designed and manufactured with provision for future expansion on each end except where the arrangement does not allow extension.

7. It shall be the manufacturer's responsibility to coordinate all necessary alignment and interconnection between component sections.

8. Enclosure shall have provisions for close coupled coordination to [MV motor controller lineup] [Load Interrupter switch line-up] [liquid type secondary unit substation transformer] [VPI dry type secondary unit substation transformer] [cast coil type secondary unit substation transformer]

9. The equipment must be shipped complete, without missing components or "ship shorts". Purchaser may waive this requirement upon request prior to shipment.

10. Louvers may be provided in the switchgear for ventilation or cooling purposes. These openings shall be filtered upon request to retard the entrance of dust. Filters shall be easily removable for maintenance. Louvers and filters, when present, shall be located on the front and rear doors.

11. The depth of the finished equipment shall be sufficient to allow for entrance, bending, and termination of power cables. Individual units shall be provided for top or bottom entrance as specified. A minimum of 26 inches of clearance between terminal pads and the cable entrance shall be provided.

12. Power circuit breakers and voltage transformer assemblies shall be drawout construction to provide maximum operator safety.

13. Safety interlocks and barriers as required by ANSI standards shall be provided to prevent personnel from inadvertent exposure to the bus while the switchgear is energized.

14. A ground bus, [.25 x 2 inch copper – for ≤50kA] [.4 x 2 inch copper – for 63kA], shall extend throughout assembly with connections to each breaker grounding contact and cable compartment ground terminal. Joints shall be made up as indicated in drawings. Station ground connection points shall be located in each end section.

15. In order to minimize condensation, each cubicle designed for outdoor application shall have a space heater.Space heaters may be wired with other space heaters in parallel and shall be provided with a single adjustable thermostat to maintain cubicle temperature at desired levels.

7. Power Circuit Breakers

1. Circuit breakers shall be rated as indicated in drawings:

1. Voltage Class: [5kV] [8.25kV] [15kV]

2. Interrupting Class: [20kA] [25kA] [31.5kA] [40kA] [50kA] [63kA]

3. Continuous Current: [1200A] [2000A] [3000A] [3500A – indoor only] [4000A force cooled – indoor only]

4. Circuit breakers of equal rating shall be interchangeable. Circuit breakers shall be operated by an electrically charged, mechanically and electrically trip-free, stored-energy spring. It shall be possible to manually charge the spring for slow closing of contacts for inspection or adjustment. Circuit breakers shall be equipped with secondary disconnecting contacts which shall automatically engage in the connected position.

5. The breaker shall include a mechanical operations counter.

6. Each circuit breaker shall be identified with an individual serial number permanently mounted on the breaker by means of a metal nameplate.

7. Each breaker compartment shall have a breaker rackout device. Using rackout device, a breaker will be self-aligning and will be held rigidly in the operating position. In the disconnect position, breaker shall be easily removable from compartment. Breaker racking shall be accomplished with door closed and latched. Insert handle through a hole in front door to operate rackout device.

8. An indicating tape shall show breaker position when racking breakers in or out of their connected positions.

9. Interlocks shall prevent moving breaker to or from operating position unless main contacts are open. Operating springs shall be discharged automatically when breaker is rolled fully into connected or disconnected position. Rackout device shall have provisions to padlock in connected or disconnected position. When locked in disconnected position, breaker shall be removable from compartment using portable lifting device. Padlock shall not interfere with breaker operation.

10. While racking in, the breaker charging motor shall be interlocked such that the charging motor is not energized until the secondary control contacts are fully engaged.

11. Automatic shutters shall cover primary disconnect stabs when breaker is withdrawn to test/disconnect position. Shutters shall be positively driven by linkages connected to racking mechanism. Gravity driven shutters are unacceptable. A stationary barrier shall be located in front of the shutters for additional safety.

12. Breaker control voltage shall be [48 VDC] [125 VDC] [250 VDC] [120VAC] [240 VAC].

13. Circuit breakers shall have a rated interrupting time of [5] [3] cycles.

14. [Circuit breaker installed in the lower compartment shall be capable of being removed from the compartment without the use of a breaker dolly once it is moved to the disconnect position (indoor and protected aisle enclosures only).]

15. [Where indicated on drawings, provide circuit breakers suitable for Class C2 capacitor switching duty.]

16. [Each circuit breaker shall be provided with a cell mounted auxiliary switch indicating whether the breaker is open or closed. Main and tie breakers shall have a [switch containing three “a” and three “b” contacts] [switch containing six “a” and six “b” contacts] [switch containing ten “a” and ten “b” contacts]. Feeder breakers shall have a [switch containing three “a” and three “b” contacts] [switch containing six “a” and six “b” contacts] [switch containing ten “a” and ten “b” contacts]. [All spare contacts shall be wired to terminal boards.]]

17. [Each circuit breaker shall be provided with a cell mounted position switch indicating whether the circuit breaker is in the “Connect” or Disconnect” position. . Main and tie breakers shall have a [switch containing three “a” and three “b” contacts] [switch containing six “a” and six “b” contacts]. Feeder breakers shall have a [switch containing three “a” and three “b” contacts] [switch containing six “a” and six “b” contacts] [All spare contacts shall be wired to terminal boards.]]

18. Main and Tie breaker closing circuits shall be wired to prevent parallel connection of the utility source through the tie breaker.

8. Power Bus

1. The main bus shall be [silver - standard)] [tin - optional] plated copper and rated as indicated in drawings. Bus bars shall have a continuous current rating based on temperature rise and documented by design tests. All joints will be [silver - standard] [tin - optional] plated with at least 2 bolts per joint. Bus bars will be braced to withstand magnetic stresses developed by currents equal to main power circuit breaker close, carry, and interrupt ratings. Access to bus bars shall be through removable front panels. Bus bars shall have fluidized bed epoxy flame retardant and non-hydroscopic insulation with a continuous current rating. The bus supports shall be polyester glass.

2. For rigidity during fault conditions all connections to roll-out potential transformer trays, and control power transformer trays shall be rigid bus bars insulated to full voltage rating of switchgear assembly.

9. Instrument Transformers

1. Current Transformers

1. Current transformer ratios are listed in each switchgear units specification paragraphs shall be as indicated on drawings. Current transformers shall be [ANSI standard accuracy] [ANSI double accuracy]. Current transformers shall be rated to withstand the mechanical and thermal stresses imposed by the momentary rating of the circuit breakers. Transformers, when mounted in switchgear assemblies, shall be rated for the full voltage of the switchgear.

2. Current transformers shall have a rated 5 ampere secondary current unless otherwise specified.

2. Voltage Transformers

1. Voltage transformers shall be drawout type such that they can be readily disengaged from the power bus. They shall be equipped with primary side current-limiting fuses and with a BIL rating which is at least equal to the switchgear. Transformer ratios are listed on drawings.

2. Where physical size restrictions do not allow the voltage transformer to be mounted in a drawout assembly, the voltage transformer may be stationary mounted with the fuses only mounted in the drawout unit. The appropriate interlocks shall be provided to insure maximum operator safety.

3. When moved to the withdrawn position, the transformer drawout unit shall automatically ground the transformer primary windings and the fuses. A visible indication of positive ground is required. The ground may be a momentary or sweeping action that occurs as the unit moved out of the connected position.

4. Voltage transformers shall have 120 volt rated secondary voltage unless otherwise specified

3. Control Power Transformers

1. Control power transformers 15kvA or smaller shall be mounted in a drawout unit. For sizes greater than 15kVA, control power transformers shall be fixed mounted in the rear cubicle, with the primary current limiting fuses mounted in a drawout unit.

2. When moved to the withdrawn position, the fuse drawout unit shall automatically ground the fuses. A visible indication of positive ground is required. The ground may be a momentary or sweeping action that occurs as the unit moved out of the connected position.

3. Each control power transformer shall have a secondary molded case circuit breaker interlocked with the drawout assembly so that the load is disconnected prior to drawout.

4. Control and Secondary Wiring

1. Secondary control wiring shall be No. 14, extra flexible, stranded, tinned-copper control wire, Type SIS cross-linked polyethylene, rated 600 volts, except for specific circuits requiring larger wire. Control wire shall be UL listed and carry a VW-1 flame retardant rating.

2. Current transformer secondary wiring shall be SIS type #10 AWG, 105 strand, extra flexible, stranded copper or larger.

3. [Crimp-type, uninsulated spade terminals shall be furnished on all wire ends, except where non-insulated ring terminals are used to connect to fuse blocks, instrument studs, or terminal block points with two or more wireconnections.] [Crimp-type, insulated spade terminals shall be furnished on all wire ends] [Crimp-type, uninsulated ring terminals shall be furnished on all wire ends] [Crimp-type, insulated ring terminals shall be furnished on all wire ends]

4. Splicing of control wire is not permitted. Control wiring must be a continuous length from terminal to terminal.

5. Secondary control wires shall be armored where they pass through primary compartments.

6. [Short circuit style terminal blocks shall be installed in current transformer secondary wiring between the current transformer and all connected devices.]

7. [Provide marking sleeves on all switchgear control wiring, heat stamped with wire origin and / or destination information.

8. Where possible, a minimum of [10%] [20%] spare terminals shall be provided in each cubicle.

10. Secondary Devices

1. Protective Devices - Protective relays shall be [specify brand] relays or other approved equivalent devices as indicated.

2. Metering - Meters/monitors shall be [specify brand] meters or other approved equivalent devices as indicated.

3. Network Communications - Provide [Ethernet switch] [other device] for interfacing the protective relays to the facility PMCS network.]

4. Provide two indicating lights (red and green) for each breaker and one indicating light (white) for each lockout relay, when provided. The indicating lights shall be Control Concepts or equal and shall be provided with LED lamps.

5. [Provide a hand-resettable lockout relay (device 86) where indicated on the drawings. The lockout relay shall disable closing of the corresponding circuit breaker until the relay has been reset. The lockout relay shall be Electroswitch Series 24 or equal.]

6. [Provide a two-position auto/manual selector switch in each breaker control circuit. Selecting “auto” will permit automatic operation. Selecting “manual” shall permit operation using the local breaker control switch. Contacts from the selector switch shall be wired to inputs on the appropriate protective relay to allow the PMCS to monitor the switch position. The switch shall be Electroswitch Series 24 or equal.]

7. [Provide [station] [intermediate] [distribution] class arresters where indicated on drawings. Arresters shall be gapless metal-oxide type with a nominal rating of [ ]kV and an MCOV of [ ]kV. The arrester shall be enclosed in a polymer housing. Arresters shall be designed and manufactured in accordance with the latest revision of ANSI/IEEE C62.11.

8. [Provide test switches on protective relays to permit trip blocking, relay isolation and testing. Test switch shall be FT style or approved equal.]

11. Accessories

1. Lift truck (1 furnished per lineup)

2. Manual racking handle (1 furnished per lineup)

3. [Test cabinet to bench test, inspect and maintain the Power/Vac breaker (optional)]

4. [Test Coupler to apply control power to the breaker outside of the cell (optional)]

5. [A ground and test device shall be provided (optional)]

6. [A remote racking device shall be provided including push-button, motor operator, and 25 feet of cable (optional)]

12. Nameplates

1. Laminated plastic engraved nameplates shall be provided. Furnish nameplates for each device as indicated in drawings. Nameplates shall be [black letters on white background] [white letters on black background]. Nameplates shall be fastened by [plastic rivets, standard] [screws, optional]. There shall be a master nameplate that indicates equipment ratings, manufacturer's name, shop order number and general information.

2. Each internal device or component shall have an identification marking.

3. Provide a mimic bus on front of the enclosure. Mimic bus shall be [adhesively backed plastic] [plastic and held in place with rivets] [[plastic and held in place with screws] [adhesively backed vinyl].

13. Finish

1. All steel structure members shall be cleaned, rinsed, and phosphatized prior to painting.

2. The switchgear shall be painted with an electrostatically applied polyester powder with final baked on average thickness between 1.5 and 4.0 mils and meet ANSI requirements for [indoor] [outdoor] equipment.

3. All exterior surfaces of the switchgear assembly shall be given final finish coats of ANSI 61 gray as standard.

4. Finish shall have a minimum pencil hardness of 2H as tested per ASTM D3363 and shall pass the ASTM B117 Salt spray test for a minimum of 1000 hours.

14. Inspection and Production Testing

1. Each circuit breaker shall be tested for proper adjustment and operation prior to shipment. The circuit breaker shall be given a minimum of 300 mechanical operations.

2. Each vacuum interrupter shall receive a vacuum integrity test by means of ac high potential test prior to shipment.

3. Each circuit breaker shall undergo a contact timing and motion velocity test.

4. Manufacturer shall maintain electronically held permanent records of each circuit breaker produced and the production test results.

5. Component bill of material shall be checked for proper quantity, description, and part number.

6. Physical dimensions shall be checked against approved drawings.

7. Equipment shall be subjected to a secondary current injection procedure to determine proper operation of all current sensitive components.

8. Equipment shall be subjected to a secondary voltage injection procedure to determine proper operation of all voltage sensitive components.

9. Complete assembly shall have a low frequency withstand (an ac high potential) test performed to assure insulation system integrity.

10. Manufacturer shall have in place a system of recording, correcting, and verifying resolution of discrepancies discovered during the inspection and testing process. The manufacturer shall be ISO 9001 certified.

11. Certified production test reports indicating satisfactory completion of all inspection and test procedures shall be available upon request.

12. Upon request the equipment shall be made available for customer inspection prior to shipment.

13. Production tests shall be performed in accordance with ANSI standards C37.20.2 and C37.09.

14. Test reports for design tests shall be available upon request.

15. Documentation

1. Drawings

1. Prior to fabrication the following drawings shall be submitted by the manufacturer for approval.

1. Front elevation view.

2. Base plan including mounting details, cable entry area, and door swing requirements.

3. Cross section view of each different section.

4. Three line diagram.

5. Component bill of material indicating quantity, description, and part number.

6. Control or schematic diagram for each different unit.

2. Following the return of approval drawings the manufacturer shall prepare and submit wiring diagrams indicating physical location of secondary control components and the appropriate wiring connections. Each control wire will be labeled. Copies of these drawings shall be submitted to the customer, upon completion, for record.

3. After the return of approval drawings, the manufacturer shall submit a record copy of any and all drawings that contained revisions.

4. After completion of the inspection and testing procedures the manufacturer shall submit a complete set of "as built" drawings. These drawings shall function as a record of the final construction of the equipment at the time it left the factory.

5. Drawings may be provided in any of the following forms as requested by the customer:

1. Digital files in the latest version of Autodesk AutoCAD.

2. Digital file format may be dwf, pdf, dgn, or dwg as specified.

6. Each drawing prepared by manufacturer shall show, at a minimum, the name, jobsite location, purchase order or contract number, and equipment identification number in addition to any information required by manufacturer.

2. Operating and Maintenance Manuals

1. As-built drawings will be provided electronically in both PDF and DWG format.

2. Instruction manuals and other final documentation will be submitted electronically in PDF format.

3. Manuals shall contain a table of contents to allow for easy reference.

3. Spare Parts List

1. Upon completion of the engineering phase, a quotation for one (1) year's recommended spare parts shall be submitted.

16. Execution

2 Examination

1 Examine installation area to assure there is enough clearance to install switchgear.

2 Check concrete pads for uniformity and level surface.

3 Verify that medium voltage metal-clad switchgear is ready to install.

4 Verify field measurements are as [shown on drawings] [instructed by manufacturer].

5 Verify that required utilities are available, in proper location and ready for use.

6 Beginning of installation indicates installer acceptance of conditions.

3 Installation

1 Installer's Certificate of ISO 9000 Compliance.

2 Installer has specialized in installing medium voltage 5 and 15 KV metal clad switchgear [with minimum [ ] years documented experience].

3 Install per manufacturer's instructions.

4 Install required safety labels.

4 Field Quality Control

1 Inspect installed switchgear for anchoring, alignment, grounding and physical damage.

2 Check tightness of all accessible electrical connections with a calibrated torque wrench. Minimum acceptable values are specified in manufacturer's instructions.

3 Megger and record phase to phase and phase to ground insulation resistance of each bus section. Megger for [1] minute(s) for each measurement at minimum voltage of [1000] VDC. Recorded values should be documented to provide a baseline for trending data which can be used to monitor insulation integrity over the expected life of the switchgear.

4 Test each key interlock system for proper functioning.

5 Adjusting

1 Adjust all [circuit breakers] [, ] [switches] [, ] [access doors] [, ] [operating handles] for free [mechanical] [ and / or ] [electrical] operation as described in manufacturer's instructions.

2 Adjust relay trip and time delay settings to values [specified] [determined] by Customer's Engineer] [as recommended in the Coordination Study provided by others].

3 Return "odd" Kirk keys to Engineer before energizing equipment.

6 Cleaning

1 Clean interiors of [switchgear] [, ] [switchboards] [, ] [panels] [, ] [separate enclosures] to remove construction debris, dirt, shipping materials. Use lint free cloth and a non-residue cleaner such as denatured alcohol.

2 Repaint scratched or marred exterior surfaces to match original finish.

For assistance regarding these specifications or with support questions, please contact Powell directly:

|Powell Electrical Systems, Inc. |713.944.6900 |

|8550 Mosley Road |Email: info@ |

|Houston, TX 77075 |Website: |

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