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TOCANA Ltd.
For
ESB Networks.
LT Panel Shrouding
Installation Guide
ESB Indoor Substations
Contents.
Background
Introduction To Formex
Tools for the job.
Reference Site
Installation Guidelines
Background.
This presentation will introduce you to the materials
required to carry out LT panel shrouding, together with
installation guidelines.
You will also be shown examples of additional equipment
that will be needed to fabricate each element of the
shrouding and how each element can be secured.
Background.
You will be shown how to get from this……..
Background.
To this……..
Introduction to Formex.
The shrouding displayed in this
presentation is fabricated from a new
product called Formex Panel.
Formex is an extruded polypropylene
which is supplied in sheet format as
illustrated.
Two master sheet sizes are available,
8’ x 4’ (2440mm x 1220mm)
4’ x 4’ (1220mm x 1220mm)
Because of its construction, Formex
Panel sheets are extremely light.
8’ x 4’ sheet = 9.56lbs
4’ x 4’ sheet = 4.78 lbs
Introduction to Formex.
Formex Panel’s unique construction, which can be
seen in fig. 1, gives the material excellent rigidity.
Formex Panel is flame retardant, rated at UL94 V0. It
has a dielectric breakdown of 60,000 volts at 6mm
thickness and a heat deflection temperature of 121
degrees C.
N.B.
NAYY Cable, manufactured to VDE 0271, has an
installation temperature range of -5 deg C to +70
deg C.
Formex Panel is non-hydroscopic.
Formex Panel can be fabricated easily by cutting,
scoring and folding which will be demonstrated later
in the presentation.
These properties make it the ideal material for this
project.
Fig. 1 Formex Panel Material.
Introduction to Formex Panel.
As outlined on the previous slide, Formex
Panel can be easily cut, scored and folded.
The ease with which this can be done will
be graphically illustrated later in the
presentation.
However at this stage its important to point
out the difference between cutting and
scoring.
Cutting requires both ‘walls’ of the panel to
be severed.
Scoring only requires one ‘wall’ to be
severed.
Introduction to Formex Panel.
Once Formex Panel has been scored correctly, it can then be folded to the required
angle. Formex Panel can be cut along each internal channel or across the channels
as indicated in the graphic below. Cutting across the channels will tend to give a
sharper bend.
’
‘Across
‘A
lo
ng
’
Introduction to Formex Panel.
Once the material has been scored, place the material against the edge of a table
along the score and snap to bend as shown below.
‘Score’
‘Use Side
Of Table
as Straight
Edge’
‘Snap’
Tools for the job.
In order to fabricate the shrouding with ease, you will require the following
items.
Item No. 1.
Approved, cutting and de-burring knives. (Use the de-burring knife to clean the
edge of the Formex Panel sheets if required)
Tools for the job.
In order to fabricate the shrouding with ease, you will require the following
items.
Item No. 2.
A folding table can be assembled easily and utilised when marking / cutting /
scoring the Formex Panel sheets.
Tools for the job.
In order to fabricate the shrouding with ease, you will require the following
items.
Item No. 3.
Approved, non-conductive measuring tape.
Tools for the job.
In order to fabricate the shrouding with ease, you will require the following
items.
Item No. 4.
Approved, Kevlar type gloves should be worn to avoid injury when cutting /
scoring / de-burring.
Tools for the job.
In order to fabricate the shrouding with ease, you will require the following
items.
Item No. 5.
3M Dual lock, which is a velcro type plastic fastening system should be used to
secure individual elements of the shrouding, either to each other or existing LT
framework.
Tools for the job.
In order to fabricate the shrouding with ease, you will require the following
items.
Item No. 5.
3M Dual lock is supplied adhesive backed. Simply remove the liner and position
as required.
Tools for the job.
In order to fabricate the shrouding with ease, you will require the following
items.
Item No. 6.
3M VHB cleaning wipes should be used to remove heavy deposits of dirt or
grease from any surface to which you are applying the Dual lock fasteners. They
should also be used to remove pen marks after fabrication.
Tools for the job.
In order to fabricate the shrouding with ease, you will require the following
items.
Item No. 7.
3M High performance cloth wipes will also be provided and should be used after
the cleaning wipes to ensure surfaces are properly prepared.
Tools for the job.
In order to fabricate the shrouding with ease, you will require the following
items.
Items No. 7 & 8.
Non permanent markers which will be provided, should be used when marking
the sheets. Non-conductive ‘T’ squares, in various sizes, will be supplied to
ensure all markings and cuts / scores are straight.
Reference Site.
In order to illustrate how the process of shrouding an LT panel in an
MV indoor substation can be carried out, a reference site was
selected. The site is located in Boyne Street, Dublin 2.
Fig. 1. below shows a section of the LT panel in the Boyne Street
substation before any work was carried out on it.
Fig. 1.
Installation guide.
Before we begin the installation guide, please remember that during
the time you are working in each substation, LT close proximity live
working procedures must be adopted.
Use mats to insulate floor along the running length of the
installation.
Installation Guide.
Fig. 1.
Step 1.
The first step in each installation is to survey and measure the
existing LT panel.
Installation Guide.
Fig. 1.
Step 2.
Once you have measured the LT panel, you can then remove the
existing flash guards between phases using insulated, approved
tools and procedures. This will make it possible to insert a back panel
which rests on the remaining bottom row of flash guards.
Installation Guide.
Step 3.
The next step is to cut a sheet of Formex Panel to the appropriate
size and shape. This first sheet will be used as a back panel which
will be positioned behind the fuses to provide a base on which to
mount the new flash guards.
Installation Guide.
Slots
Fig. 1.
Step 4.
Slots should be cut in the back panel which correspond to the
position of the fuses. This will allow it to be slotted behind them. The
back panel can be attached to the existing framework by means of
the adhesive dual-lock.
When using the dual lock please ensure to clean thoroughly any area
to which you wish to stick it as its effectiveness can be compromised
if the surface is greasy or dirty.
Installation Guide.
Scored
Fig. 1.
Step 4.
Score the top and the side of the back panel to allow the sheet to be
bent back over the top of the frame and for a return at the side to the
back wall.
Slide panel
behind fuses.
Installation Guide.
Fig. 1.
Step 5.
Slide the back panel down behind the fuse carriers into position and
secure.
Installation Guide.
Fig. 1.
Step 5.
You now have the first element of the new shrouding in place.
Installation Guide.
Fig. 1.
Step 6.
You can now begin to attach new flash guards onto the back panel
as shown in Fig.1 above. These lengths of Formex Panel will be
supplied cut to width and will only need to be cut to the appropriate
length in each case.
Installation Guide.
Horizontal
Vertical
Fig. 1.
Step 6.
Remember to use not only horizontal strips but also vertical strips to
maximise the effectiveness of the flash guards,
Vertical and horizontal strips can be seen in Fig 1. above.
Installation Guide.
Fig. 1.
Step 6.
Nearing completion of Step 6, your back panel should look
something like Fig. 1. above.
Installation Guide.
Fig. 1.
Step 7.
In the reference site, it was necessary to install shrouding around the
transformer switches to a depth that would shroud off the links
whether open or closed. To achieve this, a piece of material was cut
to size, scored and bent to allow it to be secured at right angles to
the back panel as shown above.
Installation Guide.
Sides scored
and bent back
to allow fixing
of front cover.
Fig. 1.
Step 7.
A corresponding piece was secured to the left of the transformer
switches and bracing pieces cut to size and applied internally. This
allowed for the addition of a cover to the front, enclosing the
remaining exposed areas.
Installation Guide.
Fig. 1.
Step 7.
The picture above shows the front cover in place. Please note that an
inspection window has been cut into the cover. This window will be
covered with 1.5mm clear polycarbonate on the outside to allow
operators to see if the switches are in the ‘on’ or ‘off’ position.
Installation Guide.
Side Guard
Vertical
(returned to
the wall)
Fig. 1.
Step 8.
Nearing completion, install side flash guard to cover exposed
busbars at front and to the side. Also the illustration shows where a
one-piece vertical flashguard has been put in place.
Installation Guide.
Labels
Fig. 1.
Step 9.
Once all the main elements of the shrouding are in place, labels
should be put on the shroud as illustrated above. These will help to
identify the various elements of the LT panel.
Installation Guide.
Step 10.
At this stage there were exposed fuse contacts. Special handles
have been developed to cover these contacts and they should be
installed as shown above wherever required and whenever
appropriate.
N.B. – Handles should always be fitted on exposed fuse contacts.
Installation Guide.
Handles in
place.
Step 10.
This illustration shows all exposed fuse contacts covered.
Installation Guide.
Step 11.
Finally, place the 1.5mm polycarbonate cover over the inspection
window in the front panel as illustrated above. The polycarbonate
should always be on the outside of the cover.
Installation Guide.
Your LT Panel shrouding is now complete, with all elements in
place.
Installation Guide.
Step 12.
There may also be other areas, away from the LT panel but within
the sub, where Formex Panel should be used for shrouding.
The illustrations above show additional shrouding installed in the
Boyne Street site.
Completed Installation.