Specifications Load Bank 01264011.doc

REV D SPECIFICATIONS FOR

A CONTAINERISED LOAD BANK

FOR THE TESTING OF LOW VOLTAGE ELECTRICAL POWER SYSTEMS

PART 1 GENERAL

1.1 Scope

A. Furnish and deliver a containerized resistive/reactive load bank. Each load bank shall consist of an ISO containerized constructions and remote/local controller to provide automatic operation. All load banks and control shall be the products of the same manufacturer. The electrical dimensions at 450 VAC will be 1,875 KVA; 1,500KW; and 1,125kVAR (or larger).

1.2 Codes and Standards

The load banks and controls shall conform to the requirements of (in the US):

A. Underwriter’s Laboratory

B. NFPA Standards

C. National Electrical Code The load banks and controls shall conform to the requirements of (in England):

A. EN 60204: Part 1: 2006 + AI: 2009 – Safety of Machinery. Electrical Equipment of Machines.

B. EN 61000: Part 6-3:2001 – Electromagnetic Compatibility. Generic Emission Standard.

C. EN 61000: Part 6-2:2001 – Electromagnetic Compatibility. Generic Immunity Standards.

1.3 Acceptable Manufacturers

A.

Containerized load banks shall be a ASCO Froment 8000 (or similar).

PART 2 PRODUCTS

2.1 Containerized Resistive & Inductive Combined Load Bank

A. The load bank shall be electrically operated.

B. The load bank shall be resistive and inductive for load testing from a power-factor of 1 to a power-factor of 0.8.

C. The load bank shall be enclosed in an ISO container. Due to space limitations, housing the equipment in the smallest container that holds the equipment is an advantage. The load box must be capable of being lifted with a crane using 4 attachment points that are above the center of gravity and are clear of any interferences. Pad eyes must be designated to a safety factor of 5 based upon ultimate strength and sized such that 2 pads are capable of supporting the entire load. Pad eyes shall be aligned in the plane of the lift. The submittal shall include a lifting diagram.

D. Load bank shall be forklift-able.

2.2 Electrical specifications

A.

The load step resolution shall be 1.0kW/1.0kVA as standard (or continuously variable). The load bank shall have the ability to block load (and unload), up to full load capacity.

B. The resistive load tolerance of the load bank shall be within 2.5% of total capacity.

C. The reactive load tolerance of the load bank shall be within 3% of total capacity.

D. Short-term tests with fluctuation of up to 10% above rated voltage shall be permitted.

E. Measurement System accuracy:

· Voltage +/- 0.5% plus +/- 0.2% of full scale. Resolution 0.1 V

· Current +/- 0.5% plus +/- 0.2% of full scale. Resolution 0.1 A

· Hertz +/- 0.2% Resolution 0.1 Hz F. When connected to a navy asset, all power being consumed by the load box from the unit under test will be ungrounded. The control power shall be 3-phase, grounded power with ground and neutral as required. Control power is separate from the load box test power.

G. Whips shall lug to bus bars and have a male Duraline connector on the other end. Bus Bars that accept Thomas and Betts 600 Green 94 lugs (2 hole) are preferred, but other lugs will be considered. The busbar will be able to accommodate 12 lugs per phase to use as a tie point, but 4 lugs per phase is typical. Compression fittings are not desirable. Portsmouth does not expect the load bank to arrive with lugs or whips; however, we do expect the load box to have the space for all the connections as described below:

1. Whips shall have an extra flexible, fine strand SHOF-500 MCM cable and each cable shall carry a minimum of 400A.

2. Insulator shall be Butly and Ethylene propylene rubber.

3. Whip shall be 90C cable.

4. Whip shall be rated for 600V.

5. Whip shall have an outside diameter of 1.6”.

H. The insulation resistance test upon arrival at Portsmouth Naval Shipyard, shall exceed 5 megohms at rated circuit voltage. The megger reading or on-line ground detector readings shall be conducted with all load segments turned ON as it would be when installed in a fully loaded circuit.

I. Any deviations (or alternate material) from specifications must be approved by Portsmouth Naval Shipyard Engineering Code - 230D.

2.3 Environment

The load bank shall be designed for continuous duty cycle operation in the following conditions:

A.

Ambient temperature of -10F to +100F.

B. A maximum humidity of 90% (non-condensing).

C. Altitudes up to 1000m above sea level.

D. The enclosure shall be made for being exposed to New England weather (snow and rain etc.). The phase-to-ground insulation resistance shall be maintained above 1 megohm to ground during periods of intense rain and snow.

2.4 Construction

Load Bank Enclosure A. The load bank shall be designed for outdoor operation and be completely self-contained with a freestanding ISO type container.

B. All surfaces excluding the floor are applied with a primer and top coat of marine paint.

C. The container structure shall be manufactured from carbon steel with the roof from 4.5mm and the floor from 6mm mild steel chequer plate.

D. To minimize condensation the roof shall be insulated with properly secured mineral wool (or equal).

E. All electrical enclosures must have an ingress protection rating of IP 55 (equal or greater).

F. Main power terminations, control equipment, switch gear and load element connections shall be separated into individual compartments.

G. A personnel door shall provide access to an internal control room that allows full access to the control and switch gear compartments. A suitable surface shall be provided to locate a controller.

H. Internally all live parts inside the control equipment and switch gear compartments shall be protected from accidental contact.

I. To aid serviceability, all fuses and contactors shall be individually identified. Control wiring shall be identified by wire numbers at every break (i.e. terminal strips and control devices).

J. All inductive elements shall be located at the bottom of the container.

K. Air inlet to the load elements shall be via side and end.

L. The airflow duct shall be a double wall construction to thermally isolate the exterior surfaces of the load bank from the hot airflow.

M. Each load bank shall be enclosed in a custom-made ISO intermodal shipping container. Additionally, the container shall be made for easy movement by truck, tractor or mule for over the road transportation.

N. Stencil the weight and electrical capacity (KW, KVAR, and KVA) on at least 2 sides of the box. The letters shall be a minimum of 2” in height.

Resistive elements A. Resistive load elements shall be totally weatherproof with an electrically grounded outer sheath to prevent electrical short circuits by an external foreign object and to protect personnel against accidental electrical shock.

B. Elements shall be constructed using resistance wire embedded in compact magnesium oxide powder with the outer sheath constructed from stainless steel (or equal durability construction) to provide corrosion resistance.

C. Elements shall be individually serviceable in the field without disturbance to other elements.

D. The change in resistance due to temperature shall be minimized by maintaining conservative densities.

E. To avoid reliability issues due to hot spots caused by trapped debris, elements shall not be fitted with cooling fins.

F. Open wire type elements where the live conductors are exposed and which can be short circuited to each other or to ground by foreign objects or by the breakage of an element or an element support shall not be permitted.

G. Element chambers shall be surrounded by aluminized steel heat shields reducing heat gains to the outer surface.

Inductors

A.

All inductors shall be iron cored and vacuum impregnated with insulation varnish and coated externally with a corrosion resistant paint.

B. The inductors shall have a minimum thermal classification of 180C.

C. Fuse failure of one phase leaving the inductor energized by two phases shall not cause any damage to the load inductor.

D. Inductors shall be capable of continuous operation, when absorbing power with the voltage harmonics generated by a typical AC generator complying with current standards.

E. Larger inductors shall be fitted with a discharge resistor to prolong the life of the switchgear.

Protective devices

A. Over-temperature switches shall be provided to protect against overheating in the resistive duct, each inductor and switchgear compartment. The switches shall be interlocked with the load application controls to prevent load from being applied in the event of an over temperature condition.

B. To provide for major fault protection, each element group shall have fuse/breaker protection on each phase. Fuses shall be electric shock protected and mounted to the bus bar.

C. The exterior of the load bank shall have appropriate warning/caution statements on access panels.

D. The control power shall be isolated from the power of the load being tested. 480V grounded control power: feeds 480V and 120V loads as required.

E. The load bank shall incorporate a lockable power isolator switch (lockout) within the containerized construction.

F. Switchgear enclosures shall have polycarbonate screens to protect all live parts from accidental contact.

G. Load contactors shall be interlocked with the fan to ensure that the load can only be applied when the fan is running.

Airflow and noise level

A. Hot exhaust air shall be discharged vertically for resistive, inductive load banks.

B. For movable load banks the control system shall contain phase sequence detection and automatic switching to ensure that the fan always exhausts in the correct direction.

C. The load bank (resistive inductive) shall be cooled by integral totally enclosed fan cooled motors.

D. The fan motor must be electrically protected against short circuit and from overload using a motor overload device.

E. The fan motor shall be rigidly supported by formed steel or structural members that attach to the frame of the load bank.

F. The noise level when measured 3 meters away from the load bank at 90 degrees to the airflow shall be less than a nominal: (resistive inductive)

· 10ft container: 85 dBA @ 60Hz

· 15ft container: 85 dBA @ 60HZ

· 20ft container: 88 dBA @ 60HZ

2.5 Microprocessor Control

A. The system shall be controlled by a microprocessor based module with non-volatile memory, specifically developed for load bank control and protection.

B. All instrumentation measurements shall be made from high accuracy voltage and current transformers located within the load bank.

C. Load bank calibration and configuration shall be software controlled.

D. The system shall have full three phase true RMS instrumentation.

E. A load correction circuit shall compensate for any voltage variation to ensure that the correct load is always applied. The load correction function shall be able to be turned ON or OFF as needed.

F. Control shall provide three-phase instrumentation.

G. Control system shall provide 1kW/1kVAR load step resolution.

H. There shall be a modern remote control that can control the load bank from a minimum of 1 KM away from the load bank. The cable for the remote control shall be of a standard (non-proprietary) type that shall be available from several sources.

I. Load box shall be controlled by a cable, not a through-the-air radio controller.

PART 3 OPERATION

3.1 Control hardware

A.

The load bank shall have start stop, reset buttons to enable to load bank control system. The button shall reset any error conditions including over-voltage and over-temperature.

B. Moveable load banks shall have a supply-on-test status indicator to provide information about the status of the supply-on-test.

C. The load bank shall have ACB (Air Circuit Breakers) status indicators that will illuminate when contacts on the associated ACB’s are closed (where installed).

D. The load bank shall have voltage metering source selector for voltage metering.

E. The load bank shall have a control in/out socket to control the load bank via a hand-held device.

F. The load bank shall have a power outlet and GFCI to power laptops or test gear.

G. Power for the lighting, fan, heater and control power must be supplied from the grounded power supply that is separate from the ungrounded load power.

PART 4 ADDITIONAL REQUIREMENTS

4.1 Tests and certification

A. The complete load bank shall be factory tested to ensure proper operation of the individual components and correct overall sequence of operation and to ensure that the operating voltage, frequency, capacity and control settngs are in compliance with the specification requirements.

B. The load bank manufacturer shall be certified to ISO 9001:2008 International quality standard and the manufacturer shall have third party certification verifying quality assurance in design/development, production, installation and servicing in accordance with ISO 9001:2008 (or equal).

PART 5 REQUIRED FEATURES

5.1 Control

A. Modbus

· Modbus connection point shall be directly accessible from a RS232 serial port

· Conversion from RS232 to RS485 RTU over Ethernet TCP/IP shall be available.

B. HMI System Monitor

· A large color touch screen system monitor operator interface panel shall be located internally in the load bank control room.

· The system monitor shall provide options screens for: Meters, inputs/outputs, status and load.

· Inputs and outputs shall be available to view in real time.

· The system monitor shall diagnose internal faults, verify load steps and provide a reference to faults on the electrical drawings.

· The system monitor provide local control of the load bank.

· The system monitor shall provide a detailed view of the supply-on-test instrumentation including: line voltages, phase voltages, phase rotation, currents, power and frequency.

5.2 Remote Station

A. The load bank shall have a remote control station that duplicates load bank control.

B. The remote station shall be equipped with an emergency stop button, reset button, start button and a control location selector.

C. The satellite socket(s) shall be equipped with an emergency stop button, reset button, start button and a control location selector.

5.3 Marine Paint

A. Marine paint shall meet ISO 12944-2 classification C5-M: Coastal and off-shore areas with high salinity.

B. Approximate durability period of the paint shall be 15 years before the first major maintenance work is required.

5.4 Air Inlet covers

A.

Air inlet covers shall be provided to protect from the ingress of dirt and water in transportation.

B. Inlet covers shall be top hinged and shut by key operated latches maintaining the standard ISO container dimensions.

C. Proximity switches shall be fitted to detect when the inlet covers are open and closed. Operation will be unavailable when inlet covers are closed.

5.5 Driers

A. There shall be anti-condensation heaters on the load bank.

PART 6 VISIT/TRAINING/DOCUMENTATION

6.1 Prior to Purchase

A. Representatives from Portsmouth Naval shipyard shall make sight visits prior to purchasing the load bank to ensure that the load bank can be operated on an ungrounded system with a minimum of 5 Megohms during dry operation. Each submittal shall state where a load bank is currently installed on an ungrounded system that uses an active ground detector for visiting.

6.2 TRAINING

A.

The vendor shall provide a minimum of 2 one-day trainings covering the operation, repair and maintenance at the Portsmouth Naval Shipyard for an audience of up to 15 people each day.

6.3 DOCUMENTATION

A. Detailed manuals covering the following will be included: Operation, troubleshooting, maintenance, parts list (including the manufacturer of sub-assemblies), detailed electrical schematics & interconnecting diagrams shall be specific to the load bank being delivered.

6.4 PARTS/MAINTENANCE

A. Parts will be available for a minimum of 10 years after purchase.

B. The vendor shall be able to maintain the load banks with both scheduled periodic and emergent visits to PNSY.

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