1.0 GENERAL

1.1 Summary

The following specification is intended for use by consulting engineers to provide bidding specifications for products with the quality and performance characteristics required. This specification is indexed according to the commercial standard instructions format and without this cover page has no refernce to a particular vendor or product.

1.2 System Summary

The bidder shall furnish a complete industrial power factor correction system or Synchronous Condenser, as specified herein, and hereafter referred to as the “SC”, to provide the necessary VAR’s to correct power factor reflected to the power source. The SC shall be a rotary type with regenerated true sinusoidal, phase or voltage relationship output. There shall be a full rated output breaker on the SC between the utility AC input and the synchronous generator.

1.3 Furnished with Equipment

  • Factory Test Report
  • Protective Packing
  • Installation Drawings
  • Operators Manual

1.4 Applicable Documents

1.4.1 National Electrical Code, NFPA 70-1993.

1.4.2 American National Standards Institute (ANSI).

1.4.3 NEMA Publications Number PB-1 and MG-1.

1.4.4 IEEE Standards 45.

1.4.5 Occupational Safety & Health Safety (OSHA).

1.4.6 Local Codes & Authorities having jurisdiction for this installation.

2.0 SYSTEM DESCRIPTION

2.1 The basic components of the system shall include a synchronous motor, power factor controller, a system status and control panel and a (Optional) remote annunciator panel. The complete system shall be pre-assembled and fully tested as a system prior to shipment.

2.2 The operation of the SC shall be based on automatic control of the motor field. The synchronous condenser shall remain connected to the electrical system during normal operation and shall not require any switching or produce any voltage transients that may affect other electrical systems.

2.3 The system shall be comprised of power and control section(s), which include all necessary interfaces for connection of the systems to the electrical system to be power factor corrected.

2.4 The controls shall consist of a power factor controller, voltage regulator, metering, starting logic and protective systems required for normal operation.

2.5 The synchronous condenser shall be a single system rated to supply the full load as specified herein.

3.0 SYSTEM OPERATION

3.1 During normal operation, the power factor controller will monitor the phase difference between the voltage and current on the bus to be power factor corrected. The power factor controller will convert the phase difference to a proportional voltage to be used by the voltage regulator. The voltage regulator shall provide motor field control to smoothly produce the VAR’s needed to correct the phase difference between the voltage and current monitored by the power factor controller.

3.2 After a power interruption the power factor controller will automatically restart one minute after power is restored.

4.0 QUALITY ASSURANCE

The manufacturer shall have a quality assurance program with inspection of incoming parts, modular assemblies, and final products. A final test procedure for the product shall include a check of all performance specifications and a minimum “burn in” period. An on-site test procedure shall include a check of controls and indicators after installation of the equipment.

5.0 SUBMITTALS

5.1 With Proposal: Catalog cuts and/or data sheets describing the proposed equipment shall be submitted with the proposal. A users listing shall be available giving company names locations and systems installed. All deviations from this specification shall be listed and included with the proposal.

5.2 After Receipt of Order: A minimum of two sets of installation drawings showing outline dimensions, weights, connections, and a one-line diagram of the SC shall be sent to the purchaser to be used in planning the installation of the system.

5.3 After Construction of Equipment:

5.3.1 Two copies of drawings shall be furnished of the following:

  • Equipment Installation Outline
  • Connection Diagram for External Cabling
  • Equipment Internal Wiring Diagram

5.3.2 Two instruction manuals shall be furnished and shall include, as a minimum, the following:

  • Installation Procedures
  • Operation Procedures
  • Troubleshooting Instructions
  • List of Recommended Spare Parts
  • Final Test Reports

6.0 DELIVERY, STORAGE & HANDLING

The equipment shall be shipped on a wooden pallet suitable for forklift handling. The equipment shall be covered with clear plastic sheeting to prevent dust and dirt from entering the cabinet during shipment and storage.

7.0 SITE CONDITIONS

The equipment shall be suitable for installation indoors (altitude 0 to 12,000 meters or o to 4,000 feet) with ambient temperatures from -20° to +40°C with 1% derating for each 1°C above 40°C up to 50°C, and relative humidity from 0% to 95% non-condensing.

8.0 WARRANTY

The manufacturer shall state his warranty of the equipment. In no case shall it be less than 12 months after start-up or 18 months after shipment, whichever occurs first.

9.0 PRODUCT

9.1 Electrical Characteristics

9.1.1 SC Input

9.1.1.1 System Size: Up to 20,000kVA.

9.1.1.2 Voltage/Frequency: 208, 220, 380, 415, 480, 575, 600 VAC at 60Hz or 50Hz.

9.1.1.3 Brownout: 15% Continuously low input voltage.

9.1.1.4 Voltage Transient Impulse: To 1500V for not more than 1 millisecond.

9.1.1.5 Starting Inrush: 3X Nominal input amperage.

9.1.2 SC Output

9.1.2.1 Power Factor Regulation: +/-1%.

9.1.2.2 Phase Separation: 120° +/-1° (Balanced Load), 120° +/-3° (Unbalanced Load).

9.1.3 Environmental

9.1.3.1 Ambient: 0° to 40°C (32° to 104°F) – Optional: 50°C (121°F).

9.1.3.2 Humidity: 0% to 95% Non-condensing.

9.1.3.3 Altitude: 0 to 1,000 meters (o to 3300 feet).

9.1.3.4 Audible Noise: 90dBA Open (75dBA – Optional).

9.1.3.5 Construction: Suitable for interior use. (Outdoor – Optional).

9.1.3.6 Bearings: Grease lubricated, Anti-friction Type.

9.1.3.7 Service Factor: Continuous Duty, 24 Hour Service.

9.1.3.8 Speed: 1800RPM for 60Hz, 1500RPM for 50Hz.

9.1.4 Physical Description

The SC shall consist of the following elements:

9.1.4.1 Brushless, Two bearing synchronous motor with brushless exciter. Maximum allowable temperature rise shall be 105 degrees C.

9.1.4.2 Reduced current motor starter.

9.1.4.3 Motor Controls.

9.1.4.4 Motor input circuit interrupter.

9.1.4.5 Brushless direct connected AC exciter with rotating rectifiers.

9.1.4.6 Welded steel base with spring type vibration isolators.

9.1.5 Controls

9.1.5.1 Motor Control: START switch at the SC set that activates the reduced current motor starter.

9.1.5.2 Motor Starter: Reduced current motor starting shall be provided, limiting inrush to 0.5 times nameplate amperes.

9.1.5.3 Power Factor Adjustment Range: Power factor control shall provide correction to a selected power factor between 0.8 lagging and 0.9 leading.

9.1.5.4 Operator Interface Display/Touch Screen: On-screen indications shall be provided:

  • Online
  • Offline
  • System Default
  • Auto Restart

9.1.5.5 Power Outage Protector: The synchronous condenser shall be equipped with protective relaying, and in the event of sustained power outage, the input will be tripped when the voltage decays to a preset level.

9.1.5.6 The system shall be protected from return of utility power before the motor has coasted to a stop.

9.1.6 System Status Panel

A system status and control panel shall be provided that includes all instruments and controls required for proper system operation. The system status panel (via the operator interface display/touch screen), shall have visual alarm readouts prompting the action to be taken to properly handle the situation.

9.1.6.1 System Status:

  • Offline
  • Online
  • System Default
  • Auto Restart
  • Emergency Stop

9.1.7 System Alarms

9.1.7.1 Utility Fault: This alarm shall be initiated when utility input power returns to the synchronous condenser or is out of tolerance.

9.1.7.2 System Fault: This alarm shall be initiated when any item affecting operation of the system fails.

9.1.7.3 Fault Detectors: The system shall be equipped with protective devices that shut the unit down and activate an external alarm and internal indicators. The operator interface display shall retain the fault indication after the system has shut down to simplify troubleshooting. Each fault will have a time date stamp associated with it. The following protective devices shall be provided:

  • Input/Output Voltage
  • Main Motor Under Voltage
  • Under Frequency
  • Loss of Field
  • Bearing Over Temperature
  • Winding Over Temperature
  • Start Fuse Blown
  • Start Motor Overload

9.1.8 System Controls

9.1.8.1 System Start: Engages the pony motor to bring the synchronous motor up to synchronous speed.

9.1.8.2 Emergency Stop (ESTOP): The system shall be provided with a red E-Stop push-button, that when activated, shall completely shut down the system.

9.1.8.3 Silence: Allows the operator to silence the audible alarm.

9.1.8.4 Reset: Alarm reset.

9.1.8.5 Auto Restart Enable: Allows the operator to arm this function.

9.1.8.6 The auxiliary control panel, located behind lockable doors, contains the power factor adjust.

9.1.9 System Metering

The system status and control panel shall have digital metering (1.0% accuracy) displayed on the touch screen to monitor the following functions:

  • kVAR Output of Condenser
  • System Power Factor of Corrected Source
  • Condenser Amps
  • Condenser Volts
  • % of Full Load

9.1.10 External Alarm Indication

The system shall be equipped with isolated contacts to provide remote visual and audible indications to warn operators of a potential problem and automatic restart.

10.0 CONSTRUCTION

10.1 Quality: All materials, parts, and components used will be new and of high grade.

10.2 The total system will be exposed to a functional and load test and will be subject to a factory full load test prior to shipment. Test conducted at 1.0 PF.

10.3 Maintainability: No regular maintenance service operations are required at less than one-year intervals. At installations where unusual concentrations of moisture, vapors, dust, and other particles may impinge upon windings, maintenance may be done at more frequent intervals, but without shutdown.

10.4 Warranty: The SC set shall be warranted to be free from defects in design, material, and workmanship for a period of either 12 months after installation or 18 months after shipment, whichever comes first.

11.0 EXECUTION

11.1 Manufacturing

11.1.1 The manufacturer shall design, build, test, and arrange for shipment of the SC.

11.1.2 The manufacturer shall prepare and deliver the required drawings and instruction manuals with the equipment.

11.2 Site Preparation: The owner shall prepare the site for installation of the equipment.

11.2.1 The owner shall arrange for local electricians to install the equipment.

11.2.2 The equipment shall be installed in accordance with local codes and the manufacturer’s recommendations.

11.3 Field Start-up & Inspection: The equipment is to be checked out and started by the field service representative from the equipment manufacturer.

11.4 Spares: A list of manufacturer’s recommended spare parts shall be submitted with the manuals.