Iso-Phase Bus Duct Typical Maintenance

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INSTRUCTION MANUAL
FOR THE
INSTALLATION, OPERATION AND MAINTENANCE
OF
SELF COOLED ISOLATED PHASE BUS
SUPPLIED TO
BURNS & McDONNELL.
FOR
HALTON HILLS GENERATING STATION
TORONTO, ONTARIO, CANADA
Burns & McDonnell Project No.: 5220
Burns & McDonnell Contract No.: 5220
Burns & McDonnell PO No.: 44532-C5220
Manufactured by: Spec-Fab IPB Inc.

41 Saunders Rd.
Barrie, Ontario, Canada
L4N 9A7
Spec-Fab W/O: 6340
Date: 2008-07-16
Revised: 2009-11-20
Revision: 1 Issued for construction
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TABLE OF CONTENTS
Page
1.0 TECHNICAL AND DESIGN DATA 2
2.0 GENERAL CONSTRUCTION 4
3.0 SHIPPING, STORAGE AND RECEIVING 5
4.0 INSTALLATION
4.1 Procedure 6
4.2 Connections 6
4.3 Bolted connections 6
4.4 Welded connections 7
4.5 Bolted and welded duct covers 7
5.0 COMMISSIONING AND FIELD TESTING 9
6.0 MAINTENANCE 10
7.0 BILL OF MATERIALS AND DRAWINGS 11
8.0 WELDING STANDARD 14
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1.0 TECHNICAL AND DESIGN DATA
1.1 Isolated Phase Bus:
1.1.1 GTG Units:
Operating voltage: 23KV

Current rating: 10000A
Frequency: 60Hz
Insulation rating: 60KV, 60Hz, 1 minute dry, 150KV B.I.L
(1.2 x 50 s waveform)
Short time current (1s): 160kA rms. Symmetrical
Maximum temperature rise
(Above ambient of 40C)
Conductor: 65 C
Enclosure: 40 C
Main bus: 10000A
Conductor: 394mm Octagon, 9.5mm wall.

Material: Aluminum 6101-T6, 57% of IACS.
Enclosure: 905mm ID, 4.8mm wall.

Material: Aluminum 1100-H14, 57% of IACS.
Weight: 73 kgs/linear meter.
Tap bus: 1200A
Conductor: 102mm square, 6.3mm wall.


Weight: 27 kgs/linear meter.
1.1.2 STG Units:
Operating voltage: 23KV

Current rating: 10000A
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Frequency: 60Hz
Insulation rating: 60KV, 60Hz, 1 minute dry, 150KV B.I.L
(1.2 x 50 s waveform)
Short time current (1s): 160kA rms. Symmetrical
Maximum temperature rise
(Above ambient of 40C)
Conductor: 65 C
Enclosure: 40 C
Main bus: 10000A
Conductor: 394mm Octagon, 9.5mm wall.


Weight: 73 kgs/linear meter
Tap bus: 1200A
Conductor: 102mm square, 6.3mm wall.


Weight: 27 kgs/linear ft.
1.2 Space heaters:

Rating: 240V, 750W for Main bus
240V, 300W for Tap bus
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2.0 GENERAL CONSTRUCTION
2.1 Isolated Phase Bus
The layouts of the Isolated Phase bus for Halton Hills Power Project are shown in section
7.0 on Spec-Fab drawings 6340-LA-001-A1 to 6340-LA-005-A1.
These drawings also list other drawings for particular sections and view of equipment. To
identify parts, reference should be made to the Bill of Materials in section 7.0.
As will be seen from the drawings, the bus conductor is positioned in the center of the
covers by means of four insulator assemblies. Provision is made for movement of conductors
during thermal expansion and contraction.
Reference to section 7.0 drawing STD-0-MI-001-A3 shows method of assembly. The

insulators are attached to the conductor by a bolt or a square rod for the "Anchor" type
(detail B and E) and by a square rod for the "Expansion" type (detail C). The bolt passing
through the gasket and gasket retainer, items IT-52 and IT-53, is screwed into the threaded
spacer IT-51 which will be in contact with the inside of the enclosure.
The lock nut and lock washer, IT-55 and IT-56, are put on the bolt, then the bolt is screwed
into the insulator. As the bolt is tightened, it compresses the gasket IT-52, against the outside
of the enclosure and the threaded spacer IT-51, is pull tightly against the inside of the
enclosure. The lock nut, IT-55 can now be tightened against the insulator.
This is repeated for each of the insulator and in this configuration, the insulators are always
in compression.
This bus is fully bonded by means of field welded access half covers between housing.
Access covers with handholes are supplied at all joints. The aluminum bus conductors are
connected to each other by flexible connectors, located as shown on the layout drawings.
The removable covers are insulated from the unit assemblies at one end and connected by
ground straps at the other end (one for each half cover). Reference to typical Spec-Fab
drawing 6340-JO-004-A3; which, shows the method of gasketing, insulating and positioning
the removable covers.
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3.0 SHIPPING, STORAGE AND RECEIVING
3.1 Bus units
The bus units are crated for shipping purposes. It is essential to ensure that the protective
polyester sheets applied to the end of the bus units at our plant have not been damaged
during transit.
If this has occurred, then the units must be thoroughly recleaned and a new protective cover
be applied. This cover should remain in place until the connectors and bolted covers are
ready to be installed. For extended outdoor storage, we would suggest that the units be stored
on dry ground (or on blocks) to prevent them from sitting in moisture. The equipment should
also be covered securely with a tarpaulin for protection from wind, rain etc...
3.2 Miscellaneous items
The following list is a summary of the items recommended for indoor storage, if possible.
Items as shown on Bill of Material: 6340-GTG1, 6340-GTG2 and 6340-STG

- Miscellaneous items: Item-1, 2, 3... etc.
- Connectors : C-1, C-2, C-3... etc.
- Duct covers : D-1, D-2, D-3... etc.
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4.0 INSTALLATION
4.1 Procedure
1. The Isolated Phase Bus should be installed in accordance with the field layout drawings:
2. All supporting steel must be erected on a level plane for proper bus installation.
3. Location dimensions must be verified to the layout drawings before erection of IPB is
started.
4. The installation can be started from either the transformer or the generator end.
5. The entire bus system should be erected and lined-up properly before making connections,
especially between welded sections.
6. Proper phase spacing must be maintained as shown on layout drawings: This is very
important since it may affect the electrical characteristic and proper alignment of the bus.
4.2 Connections
To ensure efficient transfer of current at the bus joints, it is important that the correct
procedure for making the joint be maintained.
4.3 Bolted connections
For bolted connections, the following procedure should be observed. Typical bolted joint is
shown on Spec-Fab drawing 6340-JO-004-A3 in section 7.0.
1. Thoroughly clean the current interchange surface with fine Emery cloth, sandpaper or wire
brush. CAUTION: This does not apply to plated surfaces.
2. Immediately coat the clean surface with NO-OX-ID Grade A Special grease. If the NO-OX-
ID grease is not applied to the cleaned surface within an hour, the surface must be recleaned
before application of the grease.
3. Complete the joint without removing the NO-OX-ID grease.
For PLATED surfaces, wipe the contact surfaces clean and lightly brush NO-OX-ID Grade
A Special grease before bolting the connectors together. Prior to final assembly, careful
inspection must be ensure that no foreign contaminants such as metal chips, wood, shaving
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etc... are sticking to the grease, as this may cause a poor contact or deterioration of the joint.
The following recommendation for torque in ft.lbs. to be used in tightening nuts on bolts
should be follow:
Torque (ft. lbs)
Bolt size SAE-5 with oversize washers
1/2 55
5/8 110
4.4 Welded connections
For aluminum welding, Spec-Fab Aluminum Welding Standard and Procedures (section 8.0)
should be followed. Precautionary measures must be taken to shield insulators from weld
splatters when welding connectors to conductor.
Once the joints have been completed, apply a thin uniform coat of Black Glyptol over the
joint (supplied by Spec-Fab).
IMPORTANT NOTE:
Where the welded type expansion connectors are supplied between sections of conductors,
one end of each connector is factory welded to the conductor to minimize field welding.
These flexible connectors are protected during shipment and care should be taken to protect
the connectors during unloading and installation. Severe deformation of the connectors may
impair its efficiency in service. Ensure Flexible connectors are returned to original shape and
closely packed after welding. For details, see typical Welded Expansion Joint.
4.5 Bolted and welded duct covers
As soon as the joints are ready to be sealed with the access covers, the insulator assemblies
should be inspected for cracks, loose hardware and chipped porcelain. Finally, the insulators,
bus and joints should be wiped clean.
When assembling bolted type duct covers, apply a thin uniform coat of Silicone grease to the
gasket as shown on the joint drawings in section 7.0. This is to prevent the gasket from
bunching up or rolling rather than sliding.
To assist in tightening up the removable covers, it is advisable to use long lead bolts at each
end. With these longer bolts, the covers can be positioned and tightened until the shorter
bolts can easily screw in. The cover must be uniformly tightened, that is, each side of the
cover should be alternately tightened.
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When the covers are tightened down onto the gasket, the lead bolts can be taken out and
replaced by the proper length of bolts. The bolts should be finally tightened do that the
covers are pulled down onto the gaskets evenly. Do not compress the longitudinal gaskets
more than 50%.
It is very important that insulation check be made between the insulated end of the
removable covers and the unit assembly. The use of a 500V Megger is recommended.
Insulation resistance should be in the Kilo-ohms range. The removable half covers may be
identified on the field layout drawings by "D" designations.
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5.0 COMMISSIONING AND FIELD TESTING
As the trouble free operating of the Isolated Phase Bus is dependent on good insulation, it is
important that dust or refuse be removed from the duct and the insulators be checked,
cleaned and dried, if necessary before closing up the covers. As a final check on insulation
before putting the unit into service, a high potential test at 45KV for one minute may be
applied to the complete installation. A DC test of 52.5KV for one minute may be applied if
an AC test transformer is not available.
IMPORTANT NOTE:
The secondary of all Current Transformers should be short circuit and grounded. The
Voltage Transformer, Capacitors and Lighting Arresters should, of course, be
disconnected for this test.
It should be noted that the porcelain insulators may be covered with moisture prior to putting
into service, and therefore, under these conditions, any Megger reading taken would be low.
The bus insulators are, however, designed to have a wet withstand characteristic to safely
allow the system voltage to be applied. Once the bus has been in service for a while, it will
be found that the moisture has evaporated and the insulation reading has risen to a
satisfactory operating level.
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6.0 MAINTENANCE
6.1 Isolated Phase Bus
Due to the access of filtered air into the bus duct, the surface of the insulators should be free
from pollution for long periods and, therefore, very infrequent inspection is all that is
required in the way of maintenance.
If the duct covers are removed, and if the gaskets, due to continuous compression, are settled
to a thickness of less than 50%, they must be replaced.
An appropriate supervision of the bus duct system can be limited to a few checks, and can be
integrated into the general unit supervision.
Only major breakdown may require an exchange of repair of individual components.
Maintenance may be grouped into the following:
(a) Regular checks
- After 3 to 6 months of operation.

- Then every 18 months of operation.
Visual checks should be directed to bolted connections between units and to other
equipment.
(b) General overhaul
General overhaul is recommended at intervals of approximately 3 to 4 years. It should be

comprise of the following:
1. Bolted connection should be uncovered and a check be made for loose or poor connections.
Change of colour of the flexible connectors may indicate overheating due to inadequate
torquing of the bolts, or degreased contact areas with possible oxidation. The connectors
must be removed, cleaned and reinstalled as per installation instruction, part 4.0 of the
manual.
2. Check insulators visually and if dust has accumulated, clean with dry "lint free Kleenex"
tissue.
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7.0 BILL OF MATERIALS AND LIST OF FIELD DRAWINGS
6340-GTG1 Bill of materials for GTG1 IPB

6340-GTG2 Bill of materials for GTG2 IPB
6340-STG Bill of materials for STG IPB
6340-LA-001-A1 IPB and associated equipment layout for GTG1
6340-LA-002-A1 IPB and associated equipment layout for GTG2
6340-LA-003-A1 IPB and associated equipment layout for STG
6340-LA-004-A1 Sectional views and details
6340-LA-005-A1 IPB and Generator Breaker support structures assembly
6340-JO-001-A3 10000A welded connection
6340-JO-002-A3 10000A welded expansion connection
6340-JO-003-A3 1200A tap bus welded connections, GTG1 & GTG2
6340-JO-004-A3 Main Transformer terminations, GTG & STG
6340-JO-005-A3 Generator Breaker connections, GTG1 & GTG2
6340-JO-006-A3 Generator connections, GTG1 & GTG2
6340-JO-007-A3 VT Surge Cubicle connections, GTG1 & GTG2
6340-JO-008-A3 Excitation Transformer connections, GTG1 & GTG2
6340-JO-009-A3 Auxiliary Transformer connections, GTG1 & GTG2
6340-JO-010-A3 Generator connections, STG
6340-JO-011-A3 1200A tap bus welded connections, STG
6340-JO-012-A3 Excitation Transformer connections, STG
6340-MI-001-A3 Space heaters wiring diagram, GTG1
6340-MI-002-A3 Space heaters wiring diagram, GTG2
6340-MI-003-A3 Space heaters wiring diagram, STG
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Reference drawings:
Bus section assembly for GTG1 & GTG2:

6340-UA-001-A2 Main bus section assembly; U1
6340-UA-016-A2 Tap bus section assembly; U16
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Bus section assembly for STG:
Miscellaneous:
STD-0-MI-001-A3 Typical insulator assembly
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8.0 WELDING STANDARDS
8.1 General Statement
These Welding Standards have been issued for the guidance of the site personnel
which are involved in the welding of IPB (Isolated Phase Bus). These standards
represent the minimum conditions that must be met in order to obtain satisfactory
quality of welds. It is the responsibility of the site contractor to assure that the
welders and procedures are qualified to the requirements of the standards required by
the owner. These standards have been produced to meet the requirements of
Canadian Standard Association standard W47.2 (Certification of Companies for
Fusion Welding of Aluminum).
The welding design, which governed the fabrication, is in accordance with the
Welding Engineering Standards of Spec-Fab Inc.
This Statement of "Requirements for Site Welding of Aluminum" for the IPB defines
the minimum requirements that must be met by the Field Contractor in order to result
in a satisfactorily erected product.
8.2 Processes
All welding will be produced by using either of the following processes:
GMAW Gas Metal Arc Welding, using a continuously fed electrode and an inert gas
for shielding of the arc (also known as MIG welding process).
GTAW Gas Tungsten Arc Welding, using a Tungsten electrode and an inert gas for
shielding of the arc (also known as TIG welding process).
The SMAW process (Shielded Metal Arc or "stick welding") is not to be used.
8.3 Qualification
All welding shall be carried out by welders certified to a recognized standard (CSA
W47.2 or ASME or AWS equivalent).
All welding shall be carried in accordance with welding procedure specifications

prepared by the welding sub-contractor and accepted by a recognized authority.
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8.4 Minimum Welding Parameters To Conform To SPEC-FAB Design Requirements
The following are considered to be minimum requirements which must be adhered to

if the electrical and mechanical design characteristics are to be satisfactorily achieved
by the required site welding operations.
8.4.1 Types of Welds
Welds shall conform to the types, sizes and locations specified on SPEC-FAB
assembly diagrams and layout drawings. Welds must not be modified from drawing
requirements without SPEC-FAB approval.
8.4.2 Storage & Handling of Consumables
Material shall be handled and stored in a manner which shall insure that the material
is protected from contamination, water staining and damage. In storing cleaned and
prepared material a protective covering, preferably polyethylene shall be used.
Workmen shall not contaminate the cleaned surfaces with oil or grease from gloves
or clothing. Welding electrode or filler wire shall be stored in a dry place where the
temperature does not fluctuate appreciably. The wire shall be stored in the original
sealed containers and not opened until required. Wire left on the welding equipment
for short periods shall be covered. Wire not being used shall be returned to the
original container and stored as above.
8.4.3 Preparation of Material for Welding
Edges for welding shall be prepared by shearing, sawing, chipping, planning or

plasma arc cutting, with the equivalent of a hand dressed finish obtained with or
without power tools.
All surfaces to be welded shall be free at the time of fit-up and welding from grease,
oil and foreign materials and shall be free from burrs, which could trap cleaning
agents.
All areas to be welded shall be cleaned back far enough so that the weld metal will
not become contaminated during welding. The distance back from the center line of
the weld will depend upon the condition of the material and the position of the joint.
The minimum distance will be 1 1/2" (38mm). Material must be welded within six
hours of being cleaned and must be protected during this period in such a manner
that it remains absolutely free of oil and foreign materials.
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The cleaning may be done chemically, with the use of suitable solvents or with the
use of a solvent followed by mechanical means such as a clean disk sander or clean
stainless wire brush depending upon the surface of the material.
8.4.4 Assembly and Fitup
The parts to be joined by fillets shall be brought in as close contact as practicable and
in no event shall they be separated more than 1/16" (1.6mm). Abutting parts to be
joined by butt welds shall be aligned to the specified tolerances in the approved
procedures.
Tack welds to be incorporated in the final welds shall be subject to the same
requirements as the final welds and both ends shall be tapered sufficiently to permit
satisfactorily fusion of weld junction.
8.4.5 Filler Metal
Filler electrode wire or filler rod shall conform to alloy 4043 for all conditions
required on the site welds of the IPB. The sizes of materials to be used shall be
determined by the welding procedure specifications of the sub-contractor. Shielding
gas shall be welding grade Argon.
8.4.6 General Notes
Where practicable the work shall be positioned so that welding is done in the flat
position.
Welds shall not be caulked.
Peening and cold working of the weld metal shall not be permitted.
Wherever feasible run-on and run-off tabs shall be employed in welding of seams.
Welds shall conform clearly to design requirements and shall have exposed faces
reasonably smooth and regular, fillet and butt weld profiles shall meet the
requirements of CSA Standard W59.2, Welded Aluminum Construction.
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8.4.7 Quality
Welds shall be free from cracks, lack of fusion, lack of penetration, undercut, overlap
or surface porosity.
All craters shall be filled to full cross section of the weld and shall be free of cracks.
Weld profiles shall meet the requirements of CSA Standard W59.2 Welded
Aluminum Construction. Weld repairs (if required) shall be carried out in accordance
with the above standard and shall be subject to acceptance by the general contractor.
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INSTALLATION, OPERATION AND MAINTENANCE

SELF COOLED ISOLATED PHASE BUS

BURNS & McDONNELL.

HALTON HILLS GENERATING STATION

TORONTO, ONTARIO, CANADA

Burns & McDonnell Project No.: 5220

Burns & McDonnell Contract No.: 5220

Burns & McDonnell PO No.: 44532-C5220

Manufactured by: Spec-Fab IPB Inc.

Spec-Fab W/O: 6340

Revision: 1 Issued for construction

1.0 TECHNICAL AND DESIGN DATA 2

2.0 GENERAL CONSTRUCTION 4

3.0 SHIPPING, STORAGE AND RECEIVING 5

4.3 Bolted connections 6

4.4 Welded connections 7

4.5 Bolted and welded duct covers 7

5.0 COMMISSIONING AND FIELD TESTING 9

7.0 BILL OF MATERIALS AND DRAWINGS 11

8.0 WELDING STANDARD 14

1.0 TECHNICAL AND DESIGN DATA

1.1 Isolated Phase Bus:

1.1.1 GTG Units:

Operating voltage: 23KV

Main bus: 10000A

Conductor: 394mm Octagon, 9.5mm wall.

Enclosure: 905mm ID, 4.8mm wall.

Weight: 73 kgs/linear meter.

Tap bus: 1200A

Conductor: 102mm square, 6.3mm wall.

Enclosure: 603mm ID, 3.2mm wall.

Weight: 27 kgs/linear meter.

1.1.2 STG Units:

Operating voltage: 23KV

Main bus: 10000A

Conductor: 394mm Octagon, 9.5mm wall.

Enclosure: 905mm ID, 4.8mm wall.

Weight: 73 kgs/linear meter

Tap bus: 1200A

Conductor: 102mm square, 6.3mm wall.

Enclosure: 603mm ID, 3.2mm wall.

Weight: 27 kgs/linear ft.

1.2 Space heaters:

2.0 GENERAL CONSTRUCTION

2.1 Isolated Phase Bus

Reference to section 7.0 drawing STD-0-MI-001-A3 shows method of assembly. The

3.0 SHIPPING, STORAGE AND RECEIVING

3.1 Bus units

3.2 Miscellaneous items

Items as shown on Bill of Material: 6340-GTG1, 6340-GTG2 and 6340-STG

4.3 Bolted connections

3. Complete the joint without removing the NO-OX-ID grease.

4.4 Welded connections

4.5 Bolted and welded duct covers

5.0 COMMISSIONING AND FIELD TESTING

6.1 Isolated Phase Bus

Only major breakdown may require an exchange of repair of individual components.

Maintenance may be grouped into the following:

(a) Regular checks

- After 3 to 6 months of operation.

(b) General overhaul

General overhaul is recommended at intervals of approximately 3 to 4 years. It should be