24 0016 8622 v15 installation of HV cable on switchgear

Installation of HV cable on
switchgear
Document no.: 0016-8622 V15
Class: RESTRICTED
Type: T09
Date: 2020-01-22

VESTAS PROPRIETARY NOTICE: This document contains valuable confidential information of Vestas Wind Systems A/S. It is protected by copyright law as an unpublished work. Vestas reserves all patent, copyright, trade secret, and
other proprietary rights to it. The information in this document may not be used, reproduced, or disclosed except if and to the extent rights are expressly granted by Vestas in writing and subject to applicable conditions. Vestas
disclaims all warranties except as expressly granted by written agreement and is not responsible for unauthorized uses, for which it may pursue legal remedies against responsible parties.


Installation of HV cable on switchgear
Document no.: 0016-8622 V15 · Class: RESTRICTED · Type: T09

Wind turbine type
Read the full document before you start to do work.
Send questions or concerns about the document to Vestas Wind Systems A/S.
Wind turbine type

Mk version

V80-2.0 MW

Mk 7–8

V90-1.8/2.0 MW

Mk 7–8

V90-2.0/2.2 MW

Mk 10

V90-3.0 MW

Mk 9

V100-1.8/2.0 MW

Mk 7, 7.1, 7.2, 7.3, and 7.4

V100-2.0 MW

Mk 7H

V100-2.0/2.2 MW

Mk 9–10

V100-2.6 MW

Mk 9

V105-3.3/3.45 MW

Mk 2

V105-3.45 MW

Mk 3A

V110-2.0/2.2 MW

Mk 10

V112-3.0 MW

Mk 0–1

V112-3.3/3.45 MW

Mk 2

V112-3.45 MW

Mk 3A

V116-2.0 MW

Mk 11B

V116-2.1 MW

Mk 11D

V117-3.3/3.45 MW

Mk 2

V117-3.45 MW

Mk 3A

V117-4.0/4.2 MW

Mk 3E

V120-2.0/2.2 MW

Mk 11C

V120-2.0/2.2 MW

Mk 11D

V126-3.3/3.45 MW

Mk 2

Page 2 of 30


Installation of HV cable on switchgear
Document no.: 0016-8622 V15 · Class: RESTRICTED · Type: T09

Wind turbine type

Mk version

V126-3.45 MW

Mk 3A

V126-3.45 MW

Mk 3B

V126-4.0/4.2 MW

Mk 3E

V136-3.45 MW

Mk 3B

V136-4.0/4.2 MW

Mk 3E

V150-4.0/4.2 MW

Mk 3E

Change description
Description of changes
Added section 12.3.2 To install the residual current transformer (KOLA 06 B2) to the
switchgear (if applicable), page 12.

Page 3 of 30

Installation of HV cable on switchgear
Document no.: 0016-8622 V15 · Class: RESTRICTED · Type: T09

Page 4 of 30

Table of Contents
1

Safety ........................................................................................................................... 5

2

Educational requirements of service technician .................................................... 5

3

Abbreviations and technical terms .......................................................................... 5

4
4.1
4.2

Referenced documentation....................................................................................... 6
Safety documents......................................................................................................... 6
Reference documents .................................................................................................. 6

5

Purpose ....................................................................................................................... 7

6

Note.............................................................................................................................. 7

7

Tools ............................................................................................................................ 7

8

Spare parts .................................................................................................................. 7

9

Consumables .............................................................................................................. 7

10

Weights........................................................................................................................ 8

11

Estimated time use..................................................................................................... 8

12
12.1
12.2
12.3
12.3.1

12.3.2

Procedure.................................................................................................................... 8
Lockout-tagout start...................................................................................................... 8
To route the HV tower cable to the switchgear............................................................. 8
To install the HV tower cable in switchgear .................................................................11
To route the conductors under the CBP ......................................................................11
To install the residual current transformer (KOLA 06 B2) to the switchgear (if
applicable) .................................................................................................................. 12
To install the conductors on the switchgear ............................................................... 16
To install the current sensor to the T-Body ................................................................. 17
To end-terminate the Nexans Euromold..................................................................... 19
To end-terminate the NKT CB24 ................................................................................ 22
To install the cable clamps ......................................................................................... 24
To install the earth conductor...................................................................................... 24
To install the switchgear cable plate........................................................................... 26
To install the cable on the tower wall .......................................................................... 26
Lockout-tagout end..................................................................................................... 29

12.3.3
12.3.3.1
12.3.3.2
12.3.3.3
12.3.4
12.3.5
12.3.6
12.4
12.5

Installation of HV cable on switchgear
Document no.: 0016-8622 V15 · Class: RESTRICTED · Type: T09

1 Safety

Page 5 of 30

0011358041

All work relating to a Vestas wind turbine, including work methods and practices, employee
training and protective measures, and use of tools and equipment, shall be in accordance with
the requirements of the applicable governmental and private occupational safety and health
codes and standards. Employers engaged in such work are also required to be familiar with and
comply with the wind turbine-specific ‘Safety regulations for operators and technicians’ manual
for the relevant wind turbine type. Vestas shall not be responsible for any liabilities arising from
failure to comply with such requirements. Vestas reserves the right to inspect such work to
ascertain such compliance.
The service technician must read and understand the PPE sheets for each of the chemicals used
or work done in this instruction. The PPE sheets describe the correct personal protective
equipment to wear for the specific work. If in doubt about the PPE requirements for the work,
contact the site responsible or the line manager and confirm the correct procedure before starting
the work.
Read the full document before you start to do work.

2 Educational requirements of service technician

0011465014

At least 2 of the service technicians who do work in a wind turbine must be able to prove that they
have a valid GWO basic safety training certificate.

At least 1 service technician must hold the wind turbine-specific training course certificate for the
wind turbine in question.
Some tasks require one or more advanced training modules or job-specific training, as described
in the Vestas technical training programme. The person who plans a specific task must make
sure that the service technicians involved have the proper know-how for the completion of that
task.

3 Abbreviations and technical terms
Table 3.1: Abbreviations
Abbreviation

Explanation

CBP

Circuit breaker panel

ECC

Energy control coordinator

GWO

The Global Wind Organisation

ICP

Incoming cable panel

HV

High voltage

LOTO

Lockout-tagout

PPE

Personal protective equipment

SDP

Switch disconnector panel

0011376388


Installation of HV cable on switchgear
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Page 6 of 30

Table 3.2: Explanation of terms
Term

Explanation

None

4 Referenced documentation
4.1 Safety documents

0011376387

Table 4.1: Safety documents
Document no.

Title

0001-0410

Personal protective equipment sheets

0004-4159

Standardised procedure risk assessment (SPRA)

Various

Safety regulations for operators and technicians

4.2 Reference documents

0011376386

Table 4.2: Reference documents
Document no.

Title

920098

Torque wrench settings

960501

Bolt connections

0018-3841

Switchgear module

0018-7497

Installation and operating manual (ABB 36 kV and 40.5 kV)

0018-7498

Installation and operating manual (Siemens 24 kV)

0056-3224

Installation and operating manual (Ormazabal)

0038-3752

HV switchgear (Mk 2–3)

0021-4798

HV switchgear operation (Mk 0–2 and Mk 8–11)

0043-4230

Switchgear technical description (Mk 10A and 10B)

0055-1011

Switchgear technical description (Mk 10C, 10D, and 11)

0065-3482

Standard service tools

0079-9393

HV switchgear (Mk 3E)

0080-2424

HV switchgear operation (Mk 3E)

0079-9641

Switchgear technical description (Mk 3E)

Unless it is specified differently, see 920098 ‘Torque wrench settings’ for information
about bolt types and bolt lubrication, and see 960501 ‘Bolt connections’ for
information about torque values.

Installation of HV cable on switchgear
Document no.: 0016-8622 V15 · Class: RESTRICTED · Type: T09

5 Purpose

Page 7 of 30

0011376385

The purpose of this document is to describe how to install the medium-voltage tower cable in the
switchgear.

6 Note

0011376384

The standard and streamline switchgear consists of 1 CBP, 1 optional ICP and 1, 2, or 3 SDPs.
The basic switchgear consists of 1 CBP.
The design of the switchgear panels (CBP and SDP) varies depending on the manufacturer.

7 Tools

0011376383

For standard service tools, see 0065-3482 ‘Standard service tools’.

Table 7.1: Tools
Item no.

Quantity

Description

VT187075

1

5–50 Nm torque wrench
ERP: TORQUE WRENCH

VT730302

1

ROUND SLING 1M SWL 1T
ERP: SLING RNEN 1m 1t

VT730499

1

ERP: CH.HOIST LH HH 0.25t 1.5m

Some tools in this tools list can vary in shape and technical specification from region
to region due to local requirements.
If in doubt, contact your local tools warehouse for tools applicable to your region.
This note may not be applicable for any special tools used in this procedure.

8 Spare parts

0011449219

Table 8.1: Spare parts
Item no.

Quantity

Description

None

9 Consumables

0011449218

Table 9.1: Consumables
Item no.
None

Quantity

Description


Installation of HV cable on switchgear
Document no.: 0016-8622 V15 · Class: RESTRICTED · Type: T09

10 Weights

Page 8 of 30

0011449217

This section is not relevant to this procedure.

11 Estimated time use

0011449216

This section is not relevant to this procedure.

12 Procedure
Risk of exposure to electric shock, arcing, flashover, fire, and explosion! SPRA
ID No. 3.19
• Do not work on live circuits.
• Obey the applicable LOTO procedures.
• Only qualified personnel are allowed to do the work.
• Make sure that the switchgear circuit breakers are open, earthed, and secured
against closing.
• Use an HV/LV voltage detector to measure zero voltage before you start to do the
work.
• Use certified and correct equipment.
• Use the necessary PPE that is given in PPE sheets 5 and 6.

12.1 Lockout-tagout start

0011426234

Isolate the part of the wind turbine where you will do the work. Obey the LOTO procedure
instruction referred to in ‘Safety documents’. If no LOTO procedure instruction is included in
‘Safety documents’, obey the LOTO instruction supplied by the site-ECC.

12.2 To route the HV tower cable to the switchgear

0011376400

In V100/V110-2.0/2.2 MW Mk 10, V116-2.0/2.1 MW Mk 11, and V120-2.0/2.2 MW Mk
11 wind turbines, the HV tower cable is supplied with or without the end terminations
for the switchgear (in this condition, the end terminations must be installed on the
bushings in the CBP).
1. Route the HV tower cable from the ladder to the CBP of the switchgear.

•

For V100-2.0 MW Mk 7H, V100-2.0/2.2 MW Mk 9, 10A, and 10B, V110-2.0/2.2 MW Mk
10A and 10B, and V112-3.0 MW Mk 0–1, see the illustration that follows.


Installation of HV cable on switchgear
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Page 9 of 30

Figure 12.1: Routing of the HV cable from the ladder to the CBP of the switchgear
1

Seen from the front of the switchgear

2

Seen from the rear of the switchgear

The wrapping must not be removed from the end terminations before they are
installed on the switchgear.


Installation of HV cable on switchgear
Document no.: 0016-8622 V15 · Class: RESTRICTED · Type: T09

•

Page 10 of 30

For V100-2.0/2.2 MW Mk 10C and 10D, V110-2.0/2.2 MW Mk 10C and 10D, V116-2.0 MW
Mk 11B, V116-2.1 MW Mk 11D, V120-2.0/2.2 MW Mk 11C and 11D, V112-3.0 MW Mk 0–1,
V117-4.0/4.2 MW Mk 3E, V126-4.0/4.2 MW Mk 3E, V136-4.0/4.2 MW Mk 3E, and V150-4.0/
4.2 MW Mk 3E, see the illustration that follows.

Figure 12.2: Routing of the HV cable on the tower wall


Installation of HV cable on switchgear
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Page 11 of 30

12.3 To install the HV tower cable in switchgear
12.3.1 To route the conductors under the CBP

1

CBP

1

CBP

2

HV grid cable connections

2

HV grid cable connections

3

HV tower cable connections

Figure 12.3: CBP in ABB switchgear

Figure 12.4: CBP in ABB basic switchgear

Basic switchgears: HV grid cables are installed on the left-hand side of the
switchgear, not on the front.

1

Remove the cable plate from the rear side of
the base frame of the CBP.

0011376399


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Page 12 of 30

Instead of a removable cable
plate, the ABB basic switchgear,
and Ormazabal switchgear has a
HV tower cable entrance in the
back of the CBP base frame.

2

Locate the CBP and open the cable compartment to access the switchgear bushings. See
the supplier documentation.

3

Open the cable compartment.

4

Route the phase, and the earth conductors
underneath the CBP.

12.3.2 To install the residual current transformer (KOLA 06 B2) to the
switchgear (if applicable)

0025178261

This procedure is applicable for the ABB switchgear only.

The residual current transformer must be installed in dry and indoor conditions.
The current sensor cable must not be moved or bent, if the temperature is below 0°C.
The secondary terminal of current transformer must be terminated to wiring from the
switchgear terminal blocks -X2-5 and -X2-6.
The residual current transformer can be installed before or after cable installation, as
the core ring can be opened into 2 halves.
It is recommended to install the residual current transformer before the cable
installation.


Installation of HV cable on switchgear
Document no.: 0016-8622 V15 · Class: RESTRICTED · Type: T09

Page 13 of 30

Figure 12.5: Switchgear cross-sectional side view of the CBP which shows the core
balance current transformer
1

Base frame

2

P2

3

Core balance current transformer

4

Earth cable

5

Cable clamp

6

T-connector with current sensor
installed

7

PE

8

Bending radius 6D (210 mm approx.)

9

P1

10

3–core-cable trifurcation point


Installation of HV cable on switchgear
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1

Put the residual current transformer at the
bottom of the switchgear base frame, such
that P1 marking is faced towards the
switchgear’s front.

Page 14 of 30


Installation of HV cable on switchgear
Document no.: 0016-8622 V15 · Class: RESTRICTED · Type: T09

2

Attach the residual current transformer to the
switchgear foundation by use of nuts cast
into the transformer frame.

3

Put the trifurcated cable phase conductors
(L1, L2, L3) through the residual current
transformer ring.

Page 15 of 30

The upper half of the transformer ring can be opened for ease of cable
installation and tightened after the installation of the cables. When you tighten
the two halves, the torque must not exceed 2.5 Nm.

4

Connect the cable earth conductor to the earth busbar, such that the cable does not go
through the residual current transformer. See the figure figure Switchgear cross-sectional
side view of the CBP which shows the core balance current transformer, page 13.


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Page 16 of 30

12.3.3 To install the conductors on the switchgear

0011376398

In the 3 MW and 4 MW wind turbines, the connectors in the phase conductors are
pre-installed from the factory.
In the 2 MW wind turbines, the connectors in the phase conductors must be installed

on the site before the cable phase conductors are installed in the switchgear.
Damage to cable terminations!
• The phase conductors must be run up to the switchgear bushings in such a way
that a minimum bending radius of 6 times the cable diameter is kept.
• The terminals in the CBP might suffer damage if they are exposed to the weight of
the cable or if the cable is twisted.
• Make sure the connectors in the CBP are not carrying the weight of the cable.

1

Remove the protection covers on the
bushings located in the CBP.

2

Install the phase conductors in the bushings. See the supplier’s instructions in the sections
that follow.

a

For supplier’s instructions to end terminate the Nexans Euromold, see section 12.3.3.2
To end-terminate the Nexans Euromold, page 19.


Installation of HV cable on switchgear
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b

Page 17 of 30

For supplier’s instructions to end terminate the NKT CB24, see section 12.3.3.3 To
end-terminate the NKT CB24, page 22

12.3.3.1 To install the current sensor to the T-Body

0020233561

This procedure is applicable for the ABB switchgear only.

The current sensor must be installed to the T-Body in dry and indoor conditions and at
temperatures between 0°C and +40°C.
The current sensor cable must not be moved or bent if the temperature is below 0°C.
Always earth the current sensor to the sensor ground terminal.

1

Attach the current sensor to the cable connector without the use of the clamping system.
A final adjustment of the sensor positioning is necessary after installation of the
final connector to the bushing.

2

Attach the current sensor (1) in the centre
measuring area of the T-Body (2).


Installation of HV cable on switchgear
Document no.: 0016-8622 V15 · Class: RESTRICTED · Type: T09

a

Put the cable of the current sensor at the top of the T-Body.

b

Use the clamping system to put the
current sensor (1) in correct position.
The maximum allowed deviation on the
circular side is 5°. The maximum
allowed deviation in the upwards/
downward direction is 5 mm.

3

Connect the current sensor (1) to the
secondary cable (2) outside the bushing.

4

Do steps 1-3 again, to install the 2 current sensors that remain.

a

Make sure that all 3 current sensors point to the same side.

Page 18 of 30


Installation of HV cable on switchgear

Document no.: 0016-8622 V15 · Class: RESTRICTED · Type: T09

5

Connect the sensor ground terminal to earth.

6

Torque the sensor ground terminal to 2–3 Nm.

Page 19 of 30

12.3.3.2 To end-terminate the Nexans Euromold

0011376397

Risk of exposure to hazardous substances and mixtures, Kema® RG-1100
Regular Grade (Anti-Seize Aluminium Pasta)! SPRA ID No. 2.02
• Toxic to aquatic life with long lasting effects.
• Use the necessary PPE that is given in sheet G. Read and obey the related SDS.

1

Clean and lubricate (2) the connector (3) and
the bushing interface (1).

2

Push the connector onto the bushing.
To get the correct applied torque there must not be lubricant on the threaded

parts.

•
•
•

See the supplier instructions that are given on the product.
For Nexans/3M™ Modular Splicing System 5835 Series, see supplier instructions.
If no instructions are available, continue to do the next steps.


Installation of HV cable on switchgear
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3

Page 20 of 30

Put the clamp screws (1) into the threaded hole of the bushing.

a

Use a torque wrench (4) with a 130 mm
extension rod (3) and a 22 mm socket
(2) to tighten the clamp screws (1) to a
torque of 50 Nm.
To get the correct applied
torque there must not be
lubricant on the threaded
parts.

4

Clean and lubricate (1) the insulating plug (2)
of the opposite side of the connector.

a

Put the plug in the connector and engage the threads.

b

Tighten the plug with hand.

c

Tighten the insulating plug assembly.

d

Use a torque wrench with a 24 mm socket and tighten the plug to a torque of 30 Nm.


Installation of HV cable on switchgear
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5

Page 21 of 30

Clean the inner surface of the voltage
detection cap (1).
The inner surface of voltage
detection cap must not be
lubricated.

a

6

Put the voltage detection cap (1) in the correct position on the connector.

Apply force to push the voltage detection cap so that the voltage detection cap is in the
correct position.


Installation of HV cable on switchgear
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12.3.3.3 To end-terminate the NKT CB24

1

Bushing (part of switchgear)

2

Assembly paste

3

Threaded pin

4

Spring washer

5

Nut

6

Insulation plug

7

Voltage detection cap

8

Connector casing

9

Stress cone

10

Earth connection

11

Earth cable lug

12

Phase conductor

Figure 12.6: NKT CB24 end termination

Page 22 of 30

0011376396


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1

Page 23 of 30

Install the threaded pin (3) in the bushing inside the CBP.

a

Torque the threaded pin to 35 Nm.

2

Clean and lubricate the contact surfaces of the connector housing (8) and the bushing (1)
interface.

3

Push the connector onto the bushing (1).

4

Install the spring washer (4) and the nut (5) on the threaded pin (3).

a

Torque the nut to 30 Nm.

5

Clean and lubricate the contact surface of the insulating plug (6) and the T-connector.

6

Install the insulation plug (6) on the T-connector.

a

7

Torque the insulation plug to 30 Nm.

Clean the inside surface of the voltage detection cap (7).
The inner surface of the voltage detection cap must not be lubricated.

8

Install the voltage detection cap (7) on the connector.


Installation of HV cable on switchgear
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12.3.4 To install the cable clamps
1

Page 24 of 30

0011597231

Install the suspension clamps around the conductors.

a

Torque the nuts to 5 Nm.
Make sure that the
connector does not hold the
cable weight.

12.3.5 To install the earth conductor
1

Locate the earthing busbar. See the supplier documentation for the location.

a

2

Location of earthing busbar (1) in the
CBP in switchgear. (This illustration is
an example).

Install the cable lug (1) of the earth conductor on the earthing busbar.

a

Torque the bolts. See the supplier documentation.

0011597441


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b

3

Page 25 of 30

Installation of earthing cable lug. (This
illustration is an example).

Connect each of the earth wires from the T-connectors to the earthing bar inside the CBP for
the Nexans T-connector.
Each connection must hold only 1 earth wire.

a

The illustration shows the earth wires
(1) on the Nexans T-connector.

b

The illustration shows the earth wires
(1) on the NKT T-connector.