Miyaneh Steel Complex: Steel Making Plant Project

MIYANEH
MME ELCO STEEL

MMTE COMPLEX
Steel Making Plant Project
ASCOTEC MMAH
DOCUMENT TITLE :Document No .Rev
:Designer Document NO DATE: NOV. 2009
NISCO
230/33 KV SUBSTATION MISP1301ETS017 2-1
ECHNICAL SPECIFICATION for
DC EQUIPMENT
:Project Document NO MWES1U43E000170012 Page: 1 of 18
DOCUMENT TYPE : Spec.

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DOCUMENT TITLE :
230/33 KV SUBSTATION
TECHNICAL SPECIFICATION for
DC EQUIPMENT
2 NOV. 09 A.Alizadeh M.Khosravian A.Hemmatian Issued For Approval
1 Aug. 09 A.Alizadeh M.Khosravian A.Hemmatian Issued For Review
Prepared Checked Approved

Rev. DATE Client Purpose of Issue
CONTRACTOR
This document and the information disclosed are the property of MMTE and are not to be used to furnish any
information for making of documents or apparatus except where approved by written agreement.
Confidential: This document discloses proprietary information. It may not be reproduced nor disclosed any person, nor used for any purpose, except with the written
.permission of MMTE
MIYANEH
MME ELCO STEEL
MMTE COMPLEX
ASCOTEC MMAH
NISCO
DC EQUIPMENT
REVISION RECORD SHEET

Note: This Table is used for External Comments
.permission of MMTE
MIYANEH
MME ELCO STEEL
MMTE COMPLEX
ASCOTEC MMAH
NISCO
DC EQUIPMENT
DC EQUIPMENT
1
1.0 GENERAL………………………………………………………………………………
…….4
2.0 DESCRIPTION…………………………………………………………………………….....6
3.0 TERMINOLOGY…………………………………………………………………………...…6
4.0 STANDARDS…………………………………………………………………………..…….6
5.0 DESIGN AND CONSTRUCTION…………………………………………………..…..…..6
6.0 SPARE PART ………………………………………………………………………........…13
7.0 SUBMITTALS ………………………………..…………………………………………..…14
8.0 INSPECTION AND TESTS………………………………………..………………………15
9.0 SUPERVISION OVER INSTALLATION AND ERECTION ……………………………16
10.0 MEASUREMENT AND PAYMENT……………………………………………………..18
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MIYANEH
MME ELCO STEEL
MMTE COMPLEX
ASCOTEC MMAH
NISCO
DC EQUIPMENT
1.0 GENERAL
1.1 SCOPE
This Specification Describes the Minimum requirements for design, inspection
and testing of DC EQUIPMENT of MIYANEH STEEL MAKING PLANT
(MIYANEH SMP).
1.2 LANGUAGE
All correspondence and submittals shall be in English.
1.3 DOCUMENT PRIORITY
In the event of any conflict between these specifications, the requisition,
drawings, codes and standards, the priority shall be given in the following order.
a. Purchase order
b. Drawings
c. This specification
d. Codes and standards
In any case vendor shall refer the matter with Purchaser and obtain clarification
before proceeding with any work.
1.4 SITE LOCATION

Site selected for MIYANEH SMP is located northwest of IRAN, at East AZERBAYJAN
Province
- Longitude : 47° 42’ E
- Latitude : 37° 27’ N
- Elevation : app. 1110 m above sea level
1.5 METEOROLOGICAL CONDITIONS.

The steel making plant to be designed and based on the following site data:
1.5.1 Ambient temperature
- Registered temperature
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DC EQUIPMENT
Highest recorded: +41.8°C

Lowest recorded: -25.6°C
Average recorded: +14.3°C

- Design conditions
Max. Ambient temperature: +20°C
Min. Ambient temperature: +6.9°C
1.5.2 Relative humidity
Relative humidity : max. %71
min. %35
1.5.3 Rainfall
Yearly rainfall : Ave. 274.6 mm
Max. Monthly rainfall : 46.1 mm
1.5.4 Atmospheric pressure
Average : 0.89 bar
Basic wind speed for design 80 km/h.
- Pollution degree : heavy pollution degree because of steel making
1.5.5. Earthquake 1
Earthquake load will be in accordance with the Iranian code of practice for Seismic
Resistant design of Building, standard 2800 (latest edition). For this project following factor
.shall be applied
Seismic zone: Region 2 (High Seismic Zone)
Design base acceleration: 0.3 G
Soil: type II
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MIYANEH
MME ELCO STEEL
MMTE COMPLEX
ASCOTEC MMAH
NISCO
DC EQUIPMENT
2.0 DESCRIPTION
Station service systems mainly shall mean 33/0.4KV auxiliary transformers, AC

distribution panels, battery chargers, battery and battery racks, D.C. distribution panels,
standby diesel generator and accessories.Work of this document includes design,
manufacture , factory testing , transportation and supervision over installation and erection
of the station DC system:
(1) Main and reserve 110 V battery charger and battery.
(2) Indoor floor mounted D.C. distribution panels.
3.0 TERMINOLOGY
Technical terminology is to be as defined in latest edition of IEC 50 and I.E.E.E 100
standards.
4.0 STANDARDS
Work of this Chapter shall comply with the requirements of latest edition of IEC, BS, DIN,
ANSI and NEMA standards within which IEC standard is preferred.
Metric SI system of units shall be applied to all dimensions and relevant

documents.
5.0 DESIGN
5.1 Battery Chargers and Battery

5.1.1 Battery Chargers.
The substation 110 V DC supply shall consist of two completely sets of battery chargers
and 1 set of battery for protection, control, signaling, alarms, emergency lighting and
motors.
The battery amper - hour capacity shall be based on an initial voltage of 2.15 Volts/cell
.permission of MMTE
MIYANEH
MME ELCO STEEL
MMTE COMPLEX
ASCOTEC MMAH
NISCO
DC EQUIPMENT
and a final voltage of 1.75 volts / cell when the battery has been discharged for 5 hours at
a continuous rate .
5.1.1.1 Detail Description

a - Control
To be provided with an auto/manual changeover switch and the facility for manual control.
b - Input
380/220 V , three phase , 50 Hz input line adjusting transformer taps plus or minus 10% .
c - Regulation
The chargers shall be within ±1% of set output voltage from no load to full load
irrespective of line and frequency variations of ±2% .
d - Stability
The chargers shall have a temperature stability of 0.05% per OC .
e - Protection
Circuit breakers shall be provided on the charger input and output circuits .
f - Output Voltage Adjustment
The float and equalize voltage shall be adjustable to plus or minus 10% .Float and
equalize charge adjustments shall be independent of each and without interaction .
The voltage shall be filtered to 2% rms , ripple with battery disconnected .
g - Timer
The chargers shall have a 30 day equalize cycle timer adjustable from 7 hours to 24 hours
, with no setting less than 7 hours .
h - Boost Charge
A conditioning charge facility shall be provided , located in the battery room and capable of
boost charging a single cell at cell terminal voltage, normal load being connected to the
battery during this period , wonder leads shall be provided to permit the charging of any
individual cell .
I - Noise
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DC EQUIPMENT
The chargers shall be equipped with filters to limit the noise below 20 db rms.
j - Output Isolation
The chargers shall incorporate diode isolation in the output circuitry to eliminate voltage
feedback from the battery plant and thus permit proper operation of an output voltage
detector circuit.
k - Output current
The chargers shall have a current limiting feature to limit the output current at 120% of
rated value and shall be maintained to short circuit .
l - Meters
The chargers shall be equipped with A.C and D.C voltage meters and ammeters.
m - Alarms
The chargers shall be equipped with the following alarms with contacts provided(wired to
a terminal strip)for annunciator display :
(I) High resistance ground detector alarm capable of a 30 kohm ground . (Local indicating
light to be provided) . The detector is required for 110 V battery. Alarm contacts shall be
provided for remote indication and enunciator display.
(II) Charger D.C. failure alarm displayed on the charger with contacts provided (wired to a
terminal strip) for annunciator display.
(III) D.C. output voltage low/high
(IV) Occurrence of equalization voltage on the operating charge.
These alarm relays shall be automatically reset .Additionally one dry “a” form contact for
alarms specified in (II) and (III) above shall be connected in parallel and wired to the
terminal strip for annunciation by the supervisory control system .
n - Capacity
The charger shall be capable of recharging the battery from 1.75 volts per cell to 2.15
volts per cell within eight hours while supplying normal other load .
5.1.1.2 Battery chargers characteristics

(1) Output voltage (V.D.C) 110 V
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MME ELCO STEEL
MMTE COMPLEX
ASCOTEC MMAH
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DC EQUIPMENT
(2) Rated current 120 A

(3) Recharging time (Hrs) 8
(4) Class Indoor

(5) Degree of protection IP 3X
(6) Ac supply available for chargers 220/380 (V.A.C.)
(7) Type of load to be supplied magnitude and duration to be assessed by tenderer
7.1 Switchgear and SCADA and telecommunication operation
7.2 Emergency lighting during standby Diesel Generator Running
5.1.1.3 Fabrication and Manufacture

A) The equipment shall be housed in a floor mounted enclosure fabricated from cold rolled
steel of a minimum thickness of 2.6 mm. All components shall be impregnated with
humidity resistant varnish.
B) Control wiring shall be thermoplastic insulated, equivalent to 2.5mm2 stranded copper
conductor and covered with a flame retarding braid.
Extra flexible wire shall be used for connections to equipment on hinged frames. Wire
ends shall be terminated on any one stud or terminal.
C) Terminal Blocks shall be of unit construction, grouped and labeled according to their
duty by strips securely attached to each terminal block. They shall be mounted to give
easy access to terminations and to enable ferrule numbers and labels to be read without
difficulty.
The terminal blocks shall have insulating barriers between points.
D) Finish
A rust preventing coat of primer shall be applied to all surfaces and finishing coats applied
shall be in accordance with chapter 2 “General Requirements“.
5.1.2 Station Batteries

5.1.2.1 General
The discharge capacity of the power supplies battery shall be sufficient to supply the
.permission of MMTE
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MME ELCO STEEL
MMTE COMPLEX
ASCOTEC MMAH
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DC EQUIPMENT
following loads during a period of 10 hours.

1- Operate all switching devices (circuit breakers, isolators etc.) within their respective
operating voltage limits.

2- Supply the normal standing load for the full discharge period.
3- Supply the emergency lighting load for a period of ten hours.
The batteries shall consist of sealed lead acid cells in sealed type units, leak proof
containers.
Covers shall be fitted with spray - proof vent plugs .
Elements shall be suspended either from ledges molded in the jar walls or from the
covers. Sufficient sediment space shall be provided so that the battery will not have to be
cleaned out during its normal life.
Cell terminal posts shall be equipped with connector bolts having acid- resisting nuts.
The power supply system (110 V battery) will operate with battery terminals free of earth.
Cell posts shall be sealed against creepage of electrolyte either by burned-ring or by lead-
alloy seal nuts.
Cells shall have sufficient electrolyte to provide for full capacity at all ratings, and shall
have a nominal specific gravity of 1.200 to 1.220 at 25oC, when the cells are fully
charged.
Electrolyte level lines shall be marked on all four sides of each jar of container.
The batteries shall be shipped dry charged with the electrolyte separate, The electrolyte
shall be added on site and the battery fully charged. Lead - plated copper intercell
connectors shall be supplied to provide 15 mm spacing between cells or units when
installed with the plates at right angles to the rack rails. The lowest rack for
accommodating battery cells shall be about 30 cms above ground level.
Each battery shall be supplied complete with intercell connectors, terminal lugs, mounting
rack and all the material necessary for it to operate in conjunction with the charger and
distribution equipment.
The cells shall be numbered and mounted on stages of wood or plastic covered steel, but
more than two stories shall not be permitted. If the batteries are located together in two
.permission of MMTE
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MME ELCO STEEL
MMTE COMPLEX
ASCOTEC MMAH
NISCO
DC EQUIPMENT
rows, there shall be enough space for maintenance access along the two long sides.
The main battery and charger protection shall be mounted as close to the battery
terminals as possible. Battery and charger cables shall be separately protected and
linked.
Battery connection cables shall be run overhead through insulated barriers into the battery
room while all other circuits shall be connected from underneath.
Nameplates shall be provided, approved by the Buyer.
5.1.2.2 Characteristics
(1) Type Sealed Lead Acid
(2) Nominal voltage (V.D.C) 110 V
(3) Variation of voltage(%) +10,-15
(4) Number of poles 2
(5) Grounding system Ungrounded
(6) Class Indoor and stationary
(7) Rated discharge period (Hrs) 5
(8) Method of charging Float
(9) Number of cells 55
(10) Rated discharge capacity Ah As per L.V.D.C. system
5.2 DC Distribution Panels

5.2.1 General
The battery charger switching distribution panel shall contain molded case circuit breakers
and shall feed the local distribution panels .
The local distribution panels shall contain a main disconnect switch and high rupture
capacity fuses or suitable graded MCB’S as per drawings for local D.C. distribution .
5.2.2 Construction
The panels shall be dead front type , floor mounted with modular steel enclosures and
.permission of MMTE
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MME ELCO STEEL
MMTE COMPLEX
ASCOTEC MMAH
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DC EQUIPMENT
lockable hinged doors . All elements shall be arranged so that access may be made to
them from the front for easy installation , maintenance and replacement .
Openings not used for breakers shall be covered by removable steel plates
The panels shall be 2 wire for ungrounded D.C voltage .
Suitable arrangements shall be made for the glanding and terminating of all cables
entering and leaving the distribution panel in a manner that allows the addition of future
cables as required .
5.2.3 Circuit Breakers

The circuit breakers shall be 250 volts D.C. double break, draw out type, molded case
type suitable for 110V. D.C. ungrounded system and 45oc indoor ambient temperature.
The circuit breakers shall be equipped with thermal and adjustable magnetic trip for co-
ordination with the fuses in the local distribution panels.
Circuit breakers shall be provided with a handle padlock attachment to enable the breaker
to be padlocked in the open or closed position.
Panel main circuit breaker shall be provided with a trip alarm contact for remote indication.
All circuit breakers shall be provided with trip position indication to clearly indicate the
breaker trip position.
Sufficient number of circuit breakers should be provided to feed the panel boards, DC
power supply to the relay and control panels in control and switchgear building,
emergency lighting, and all other equipment requiring D.C. power.
A minimum of 20% spare D.C. breakers shall be provided.
D.C. circuit breakers shall be suitable for 10,000 amps system fault level. The minimum
number and rating of 110 V DC circuit breakers shall be in accordance with the relevant
drawings.
5.2.4 Disconnect Switches

Disconnect switches shall be air break, manually operated, 2 pole and suitable for 250volt
D.C. operation.
.permission of MMTE
MIYANEH
MME ELCO STEEL
MMTE COMPLEX
ASCOTEC MMAH
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DC EQUIPMENT
5.2.5 Fuses
The fuses shall be high rupture capacity rated for 250 V DC with visible indication of
operation.
5.2.6 Accessories
A spare heater and thermostat shall be provided to prevent condensation. The heater shall
be located near the lower part of the panel.
All terminals shall be solder less clamp type.
The necessary ground lugs shall be provided for grounding the panel , and all other
necessary accessories shall be provided .
5.2.7 Nameplates
Engraved nameplates shall be supplied as follows :
(i) Panel nameplates on the front of the panel approximately 15mm x 80mm.
(ii) Nameplates identifying each distribution circuit .
5.2.8 Panel characteristics

(1) Nominal service voltage (V.D.C.) 110 V 48 V
(2) Number of poles 2 2
(3) Class Indoor Indoor
(4) Degree of Protection IP42 IP42
6.0 SPARE PARTS ( DC supply)

The following mandatory spare parts shall be provided to cover each D.C. , A.C. system
installed where applicable :
one (1) - Transistor for each type used .
one (1) - Diode for each type used .
one (1) -Litre - Touch - up paint .
.permission of MMTE
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MME ELCO STEEL
MMTE COMPLEX
ASCOTEC MMAH
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DC EQUIPMENT
one (1) - Printed circuit card for each type used .

Twenty (20) - Lamps for each type used .
one (1) - Relay for each type used .

one (1) - SCR for each type used .
Ten (10) - Intercell connectors .
Ten (10) - Terminal lugs compression type suitable for
35mm2 and 70mm2 insulated copper conductor
Two (2) - Complete cells for 110 V D.C. batteries .
20% - Auxiliary contacts for each type used .
10% - Each size of miniature C.B. used .
one (1) set - Wrenches and other tools necessary for
assembling and disconnecting the battery units (to
be itemized by tenderer with offer .
10% - Each size of molded case circuit breaker used .
10% - Each size of fuses used .
Two (2) - Each size of fused switch used .
Sufficient electrolyte reserve - for sixty months .
7.0 SUBMITTALS
7.1 Calculation Sheets
Submit four (4) copies of all calculations to establish adequacy , in any respect, of the
station service equipment selected for the specified duties under all power system
operation conditions from normal to the most severe fault conditions envisaged in
accordance with Submittals chapter 3 .
7.2 Shop Drawings and Manufacturer’s Literature

Submit electrical design , fabrication and erection drawings for this chapter in accordance
with the Article entitled “Shop Drawings” in submittals chapter 3 .
The following shall be considered a minimum .
.permission of MMTE
MIYANEH
MME ELCO STEEL
MMTE COMPLEX
ASCOTEC MMAH
NISCO
DC EQUIPMENT
(1) Technical Specification

(2) Outline drawings
(3) Assembly drawings

(4)Control schematic and wiring diagrams for the charger , moulded case C.B’s , Diesel
gen . , etc ...
(5) Spare parts bulletins
(6) Shipping and packing details
7.3 Test Reports

Submit four (4) copies of all final type test and routine test reports together with the
certification of compliance of the equipment with the type and routine tests stipulated in
the applicable standards .
7.4 Maintenance Data and Operating Instructions

Submit maintenance manuals for this chapter in accordance with Article entitled “
Maintenance Manuals.
8.0 INSPECTION AND TESTS

Perform all inspection , routine and type tests stipulated in applicable standards to ensure
that material and workmanship conform to the specification and drawings .
Give Client’s representative access to the work for determination or assessment of
compliance with the provision of this specification or to witness the contractor’s inspection
or tests .
Produce a certificate of compliance of the equipment with the design , routine and type
tests stipulated in the applicable standards .
In addition submit satisfactory evidence of the equipment having successfully undergone
at least the following tests , before delivery to site :
(1) Operation of all meters and relays using single phase or three phase supply as
required, including operation of relay contacts.
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DC EQUIPMENT
(2) Energizing of all low voltage control circuits using the appropriate voltage supply , and
testing for operation and sequence of operation ; polarity tests where required .
(3) Di-electric strength test at 1500 volts A.C. on all wirings .

(4) Continuity of all low voltage circuits .
Client’s representative reserves the right to have a representative present during final
shop and functional testing and , so that it may be possible to take advantage of this , the
contractor shall advise the date of test at least sixty (60) days in advance.
9.0 SUPERVISION OVER INSTALLATION,ERECTION

Perform visual inspection before installation to ensure that there is no damage resulting
from shipment .
Supervise over installations , erection and commissioning of the station service equipment
to ensure satisfactory and proper operation in every respect .
This supervision shall cover but not be limited to the following where applicable :
(1) Installing the equipment in accordance with the drawing and the manufacturer’s
instructions .
(2) Assembling and erecting battery racks .
(3) Cleaning and setting the cells on the racks .
(4) Installing inter-cell links and cables .
(5) Filling battery cells links and cables .
(6) Installing battery chargers .
(7) Installing indoor and outdoor D.C./A.C. distribution panels .
(8) Installing diesel generator and its control cubicles , fuel tanks and accessories .
(9) Interconnecting equipment .
(10) Inspecting , making necessary adjustments , field testing , and place the equipment in
commercial service .
(11) Notifying Client’s representative in writing as soon as installation of the equipment is
completed .
(12) On completion of the installation , carrying out all tests subject to the requirements
.permission of MMTE
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and operating conditions of the client system in co-operation with and in presence of
client’s representative and in accordance with a program approved by him .
(13) Performing field tests and inspections including but not limited to the following :
(a) Visual inspection and checks
Hardware and mounting .
Grounding connections .
Check of fuse and C.B. ratings .
Check of thermal relays .
Check of level and specific gravity of the electrolyte in each cell.
(b) Charger output voltages
Polarity check .
Normal output voltage .
Raised output voltage .
Adjusted current (in position of boost charge).
Boost voltage .
(c) Alarm Tests
Loss of DC.
Loss of AC.
DC output voltage low/high
Earth fault test .
(d) Insulation resistance of battery connections .
(e) Charging the batteries and providing charging chart according to charging instructions .
(f) Operational capacity test (discharging batteries according to instructions )
(g) AC and DC circuit breakers overcurrent and thermal tests .
(h) Continuity test of all low voltage circuits .
(i) Meggering on al low voltage circuits .
(j) Check of the operation of all meters , relays, instruments, alarms and trips .
(k) Functional testing of all equipment .
(l) Starting up diesel generator , putting on the load and checking the circuits and functions
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(m) Fuel motor pump test .

(n) Automatic fire protection test .
10.0 MEASUREMENT AND PAYMENT

Payment of this chapter will be a lump sum for each substation and will be made in
accordance with the Schedule of Prices .
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MIYANEH

MME ELCO STEEL

DOCUMENT TYPE : Spec.

2 NOV. 09 A.Alizadeh M.Khosravian A.Hemmatian Issued For Approval

1 Aug. 09 A.Alizadeh M.Khosravian A.Hemmatian Issued For Review

Prepared Checked Approved

REVISION RECORD SHEET

Note: This Table is used for External Comments

1.4 SITE LOCATION

1.5 METEOROLOGICAL CONDITIONS.

Highest recorded: +41.8°C

Average recorded: +14.3°C

Station service systems mainly shall mean 33/0.4KV auxiliary transformers, AC

Metric SI system of units shall be applied to all dimensions and relevant

5.1 Battery Chargers and Battery

5.1.1.1 Detail Description

5.1.1.2 Battery chargers characteristics

(2) Rated current 120 A

(4) Class Indoor

5.1.1.3 Fabrication and Manufacture

5.1.2 Station Batteries

following loads during a period of 10 hours.

operating voltage limits.

5.2 DC Distribution Panels

5.2.3 Circuit Breakers

5.2.4 Disconnect Switches

5.2.8 Panel characteristics

6.0 SPARE PARTS ( DC supply)

one (1) - Printed circuit card for each type used .

one (1) - Relay for each type used .

7.2 Shop Drawings and Manufacturer’s Literature

(1) Technical Specification

(3) Assembly drawings

7.3 Test Reports

7.4 Maintenance Data and Operating Instructions

8.0 INSPECTION AND TESTS

(3) Di-electric strength test at 1500 volts A.C. on all wirings .

9.0 SUPERVISION OVER INSTALLATION,ERECTION

(m) Fuel motor pump test .

10.0 MEASUREMENT AND PAYMENT

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