NS253 Termination of Wiring in Substation Protection and

Transcription

Network Standard
NETWORK
NW000-S0038
NW000-S0038
Document No
Amendment No
Approved By
Approval Date
Review Date
:
:
:
:
:
NW000-S0038
0
Chief Engineer
26/06/2015
26/06/2018
NS253 TERMINATION OF WIRING IN SUBSTATION PROTECTION
AND CONTROL EQUIPMENT
UNCONTROLLED IF PRINTED
Page 1 of 28
NS253 Termination of wiring in substation protection and control equipment
Amendment No 0
ISSUE
For issue to all Ausgrid and Accredited Service Providers’ staff involved with the termination of wiring in substation protection
and control equipment, and is for reference by field, technical and engineering staff.
Ausgrid maintains a copy of this and other Network Standards together with updates and amendments on www.ausgrid.com.au.
Where this standard is issued as a controlled document replacing an earlier edition, remove and destroy the superseded document
DISCLAIMER
As Ausgrid’s standards are subject to ongoing review, the information contained in this document may be amended by Ausgrid at any
time. It is possible that conflict may exist between standard documents. In this event, the most recent standard shall prevail.
This document has been developed using information available from field and other sources and is suitable for most situations
encountered in Ausgrid. Particular conditions, projects or localities may require special or different practices. It is the responsibility of
the local manager, supervisor, assured quality contractor and the individuals involved to make sure that a safe system of work is
employed and that statutory requirements are met.
Ausgrid disclaims any and all liability to any person or persons for any procedure, process or any other thing done or not done, as a
result of this Standard.
All design work, and the associated supply of materials and equipment, must be undertaken in accordance with and consideration of
relevant legislative and regulatory requirements, latest revision of Ausgrid’s Network Standards and specifications and Australian
Standards. Designs submitted shall be declared as fit for purpose. Where the designer wishes to include a variation to a network
standard or an alternative material or equipment to that currently approved the designer must obtain authorisation from the Network
Standard owner before incorporating a variation to a Network Standard in a design.
External designers including those authorised as Accredited Service Providers will seek approval through the approved process as
outlined in NS181 Approval of Materials and Equipment and Network Standard Variations. Seeking approval will ensure Network
Standards are appropriately updated and that a consistent interpretation of the legislative framework is employed.
Notes: 1. Compliance with this Network Standard does not automatically satisfy the requirements of a Designer Safety Report. The
designer must comply with the provisions of the Workplace Health and Safety Regulation 2011 (NSW - Part 6.2 Duties of designer of
structure and person who commissions construction work) which requires the designer to provide a written safety report to the person
who commissioned the design. This report must be provided to Ausgrid in all instances, including where the design was
commissioned by or on behalf of a person who proposes to connect premises to Ausgrid’s network, and will form part of the Designer
Safety Report which must also be presented to Ausgrid. Further information is provided in Network Standard (NS) 212 Integrated
Support Requirements for Ausgrid Network Assets.
2. Where the procedural requirements of this document conflict with contestable project procedures, the contestable project
procedures shall take precedent for the whole project or part thereof which is classified as contestable. Any external contact with
Ausgrid for contestable works projects is to be made via the Ausgrid officer responsible for facilitating the contestable project. The
Contestable Ausgrid officer will liaise with Ausgrid internal departments and specialists as necessary to fulfil the requirements of this
standard. All other technical aspects of this document which are not procedural in nature shall apply to contestable works projects.
INTERPRETATION
In the event that any user of this Standard considers that any of its provisions is uncertain, ambiguous or otherwise in need of
interpretation, the user should request Ausgrid to clarify the provision. Ausgrid’s interpretation shall then apply as though it was
included in the Standard, and is final and binding. No correspondence will be entered into with any person disputing the meaning of
the provision published in the Standard or the accuracy of Ausgrid’s interpretation.
KEYPOINTS
This standard has a summary of content labelled “KEYPOINTS FOR THIS STANDARD”. The inclusion or omission of items in this
summary does not signify any specific importance or criticality to the items described. It is meant to simply provide the reader with a
quick assessment of some of the major issues addressed by the standard. To fully appreciate the content and the requirements of the
standard it must be read in its entirety.
AMENDMENTS TO THIS STANDARD
Where there are changes to this standard from the previously approved version, any previous shading is removed and the newly
affected paragraphs are shaded with a grey background. Where the document changes exceed 25% of the document content, any
grey background in the document is to be removed and the following words should be shown below the title block on the right hand
side of the page in bold and italic, for example, Supersedes – document details (for example, “Supersedes Document Type
(Category) Document No. Amendment No.”).
NW000-S0038
Page 2 of 28
KEY POINTS OF THIS STANDARD
Scope and Risks Addressed
Terminals
Lugs and cable terminations
This s This standard is limited to scope
identified below and provides controls for
associated risks as listed below:
This section defines the terminal styles in use
for different applications and includes review of
terminals for:
The lugs and cable terminations to be used
within Ausgrid are defined in this section. The
section includes:








Terminals for Protection Relays, SCADA,
Battery Links, Test Links, and Fuse
Bases.
Lugs and cable terminations.
Crimping Techniques
Protection
SCADA
Battery terminals
Crimping
This section identifies the type of crimping tool
to be used for different types of
terminations/lugs.
Approved lug types
Cable termination methodologies
Where to for more information?
Section 5.2
Section 5.3
Section 5.4
Tools and Forms
Tools and Forms
Tools and Forms
Section 1, 2
Annexure A – Lug stock codes
Annexure C – Relay specific terminations
Annexure B – Crimping tools
Annexure D – Sample Compliance Checksheet
NW000-S0038
Page 3 of 28
Amendment No 0
Network Standard
NS253
Termination of Wiring in Substations Protection and Control Equipment
Contents
1.0
PURPOSE ............................................................................................................................................. 5
2.0
SCOPE .................................................................................................................................................. 5
3.0
REFERENCES ...................................................................................................................................... 5
3.1
Ausgrid documents .................................................................................................................... 5
3.2
Other standards and documents................................................................................................ 5
3.3
Acts and regulations................................................................................................................... 5
4.0
DEFINITIONS ........................................................................................................................................ 6
5.0
TERMINATION OF WIRING .................................................................................................................. 7
5.1
General ...................................................................................................................................... 7
5.2
Terminals ................................................................................................................................... 7
5.2.1 Protection ....................................................................................................................... 7
5.2.2 SCADA ........................................................................................................................... 7
5.2.3 Moulded battery or test links .......................................................................................... 8
5.2.4 Red spot back stud connected fuse holder .................................................................. 10
5.3
Lugs and cable terminations .................................................................................................... 11
5.3.1 Lugs .............................................................................................................................. 11
5.3.2 Cable terminations ....................................................................................................... 12
5.4
Crimping ................................................................................................................................... 13
6.0
RECORDKEEPING ............................................................................................................................. 14
7.0
AUTHORITIES AND RESPONSIBILITIES .......................................................................................... 14
8.0
DOCUMENT CONTROL...................................................................................................................... 14
ANNEXURE A - LUG STOCK CODES ........................................................................................................... 15
ANNEXURE B - CRIMPING TOOLS ............................................................................................................... 16
ANNEXURE C - RELAY SPECIFIC TERMINATIONS .................................................................................... 18
ANNEXURE D – SAMPLE COMPLIANCE CHECKLIST ................................................................................ 27
NW000-S0038
Page 4 of 28
1.0
Amendment No 0
PURPOSE
The purpose of this standard is to standardise the types of cable termination methods, lugs, and
crimping tools used across the Ausgrid Network in the wiring of substation control and protection
panels and other related substation equipment.
2.0
SCOPE
The following is included:
 New work
 Secondary wiring lugs, terminals, links, fuse holders, and the associated crimping tools to be
used
The following is not included:
 The wiring in equipment supplied to Ausgrid covered by purchase orders or period contracts in
which the method of wiring has been approved as part of the contract.
3.0
REFERENCES
All work covered in this document shall conform to all relevant Legislation, Standards, Codes of
Practice and Network Standards. Current Network Standards are available on Ausgrid’s Internet
site at www.ausgrid.com.au.
3.1
Ausgrid documents










3.2
Company Form (Governance) - Network Document Endorsement and Approval
Company Procedure (Governance) - Network Document Endorsement and Approval
Company Procedure (Network) - Production / Review of Network Standards
Electrical Safety Rules
Electricity Network Safety Management System Manual
NS181 Approval of Materials and Equipment and Network Standard Variations
NS203 Telecommunications: Master Policy Document
NS212 Integrated Support Requirements for Ausgrid Network Assets
NS252 Requirements for wiring within panels
NS261 Requirement for Design Compliance Framework for Network Standards
Other standards and documents
 ENA Doc 001-2008 National Electricity Network Safety Code
 WSI302 Manufacture of Protection Panels
3.3
Acts and regulations
 Electricity Supply (General) Regulation 2014 (NSW)
 Electricity Supply (Safety and Network Management) Regulation 2014
 Work Health and Safety Act 2011 and Regulation 2011
NW000-S0038
Page 5 of 28
4.0
Amendment No 0
DEFINITIONS
Accredited
Service Provider
(ASP)
An individual or entity accredited by the NSW Government Trade &
Investment in accordance with the Electricity Supply (Safety and Network
Management) Regulation 2014 (NSW).
Business
Management
System (BMS)
An Ausgrid internal integrated policy and procedure framework that contains
the approved version of documents.
Crimp
An electrical connector that is compressed onto a conductor
Document
control
Ausgrid employees who work with printed copies of document must check
the BMS regularly to monitor version control. Documents are considered
“UNCONTROLLED IF PRINTED”, as indicated in the footer.
Lug
A conducting fitting that can be connected to an electrical conductor
Network
Standard
A document, including Network Planning Standards, that describes the
Company's minimum requirements for planning, design, construction,
maintenance, technical specification, environmental, property and metering
activities on the distribution and transmission network. These documents are
stored in the Network Category of the BMS repository.
Panel
The cubicle in/onto which protection and control equipment is mounted.
Panel may also refer specifically to the front sheet metal to which relays are
mounted and then fixed to the rest of the cubicle.
Review date
The review date displayed in the header of the document is the future date
for review of a document. The default period is three years from the date of
approval however a review may be mandated at any time where a need is
identified. Potential needs for a review include changes in legislation,
organisational changes, restructures, occurrence of an incident or changes in
technology or work practice and/or identification of efficiency improvements.
Terminal
A point of connection for closing an electric circuit
NW000-S0038
Page 6 of 28
5.0
TERMINATION OF WIRING
5.1
General
Amendment No 0
A basic summary of the requirements in this document is as follows: Compression type solderless lugs shall be used at the terminations of all stranded wires.
 The termination of bare wire strands into terminals is not permitted.

The lugs shall be manufactured from high conductivity seamless copper tube stock and the
correct size lug shall be used to suit the wire size.
 All lugs shall be crimped with the correct compression crimping tool recommended by the lug
manufacturer.
 The shank of the lug shall be protected by insulating tubing to prevent direct or accidental
contact with adjacent terminations.
 Under no circumstances shall lugs be bent, filed, cut or modified in any way to fit a termination.
The lug’s insulation shall not be removed.
 On completing all crimps a visual inspection and pull test should be carried out to ensure that
there is no movement of the wire inside the ferrule within the crimped connection. All crimped
indents shall be on the top of the lug and visible.
5.2
Terminals
5.2.1
Protection
For details of protection terminals see Ausgrid layout and wiring diagrams. In most instances, Utilux
H3820 terminals are employed for protection wiring, including DC.
Figure 1: H3820 Terminals
5.2.2
SCADA
SCADA wiring is generally a smaller cross sectional area (CSA) than control and protection cabling
and hence Utilux H3820 terminals are not used as terminals for SCADA. Weidmuller type terminals
are generally used for termination of SCADA.
Weidmuller terminals are used for SCADA wiring, examples of common types are listed below: SAKR – link terminal
 ASK1 – fuse terminal
NW000-S0038
Page 7 of 28





Amendment No 0
SAK 2.5 – terminal up to 2.5mm² wire
SAK 4 – terminal up to 4mm² wire
AKZ 4 – terminal up to 4mm² wire
AKZ 4L – terminal up to 4mm² wire with solder tag
EKZ 4 – earth terminal up to 4mm² wire
Figure 2: SAKR Terminals
5.2.3
Moulded battery or test links
Test links and battery links are to be mounted so if the sliding section is loosened, it will fall to the
open position.
Most protection panels use moulded battery or test links. The links shall be installed as shown in
Figure 3. The links can be obtained from Ausgrid store, with the stock code shown in Annexure A.
All terminations to moulded battery or test links shall use the nut/washer combination as outlined in
Figure 4.
NW000-S0038
Page 8 of 28
Amendment No 0
Figure 3: Moulded type link assembly
Figure 4: Connections on to a stud
When terminated all connections must have at least 1 thread of the stud protruding from the end of
the nut. All lug terminations nuts shall be torqued to 4nm utilising a torque wrench.
All fixing such as washers and nuts are to be stainless steel S.S AISI 304, spring washers are to be
stainless steel S.S AISI 316.
The front of all links should be checked to ensure that all washers are present, nuts are free to
move and sliding link will fall open. There have been instances of the stainless steel nuts locking
onto the 6mm threads by the process of galling. The incorrect use of battery drills, that is using
battery drills on high speed to attach nuts, will cause galling.
The back panel link assembly holding nut is to be checked for tightness using a PE test spanner
which is displayed in Figure 5. The tightness is to be checked only when the cable connections
have been made.
Figure 5: PE test spanner
NW000-S0038
Page 9 of 28
Amendment No 0
Figure 6: PE Test Spanner being used to check back panel holding nut
Figure 7: PE Test Spanner being used to check back panel holding nut
5.2.4
Red spot back stud connected fuse holder
Wiring connected to the 6 millimetre stud employing the same techniques as for the moulded test
links. Red spot fuses are supplied with brass half nuts, these are to be replaced with full brass nuts.
NW000-S0038
Page 10 of 28
Amendment No 0
Figure 8: Red spot back stud connected fuse holder
5.3
Lugs and cable terminations
5.3.1
Lugs
The lugs and terminals used throughout Ausgrid in particular for relays and terminal blocks require
specific types of lugs to be used as outlined in Annexure A.
Under no circumstances should lugs be modified in any way to fit a termination. This includes
bending the lugs; all lugs used are to be pre – insulated.
5.3.1.1 Solid barrel lugs
As a rule all protection cabling shall be terminated using solid barrel lugs , this type of lug used in
Ausgrid is the Utilux heavy duty lug which is available in flat or 90 degree palm. H series lugs must
be used when terminating to stud type terminal blocks and relays. In some cases this is not
possible as Utilux and other manufacturers do not make a heavy duty pre-insulated straight lug
with a 4.1mm hole therefore ring terminal lugs outlined in Figure 9 may be used.
5.3.1.2 Split lugs double grip
Double grip Split lugs are permitted if constructed as in Figure 9 and are to be used on control
wiring only, these lugs are manufactured by Utilux and Cabac and wire sizes are colour coded.
RED = 1.5mm
BLUE = 2.5mm
YELLOW = 6mm
These lugs are available in ring terminal, fork spade, lip blade, flat blade, pin blade and bootlace
ferrules.
NW000-S0038
Page 11 of 28
Amendment No 0
5.3.1.3 Crimp links / in-line splice
Under no circumstances will jointing or splicing of control or CT cables be allowed. Control and CT
cables should be continuous from source to destination; however where continuous cables are not
practicable connection shall be achieved via terminal blocks in a marshalling cubicle.
5.3.2
Cable terminations
Cables shall be terminated in the following way:
 Stranded conductors shall be terminated by means of approved pre-insulated crimpable circular
lugs.
 The Conductive parts of all terminations shall comprise of copper material with tinned
electroplating to avoid corrosion build up.
Figure 9 shows the construction and various types of these terminations.
With the exception of bootlace terminations, the remaining terminations shall be constructed from:
 Solid barrel heavy duty type such as the Utilux H series or
 A two stage crimpable copper material such as the Utilux or Cabac colour coded lugs.
For the two stage crimpable copper material, the first stage comprising of a main conducting part,
shall fit stranded conductor, and the second stage, comprising of a copper barrel sleeved over the
main conducting barrel, shall fit the cable insulation to provide a strong grip to the cable end.
Special application terminals such as pre-insulated right angle or L circular ring terminals used for
Midos or similar protection range, and pre-insulated quick fork terminals are also acceptable. For
dual cable connections, circular lugs may be used. Quick fork lugs may only be used when captive
type screws are present on the clamping unit of terminal blocks. See Annexure A for the lug stock
codes.
The size of each termination shall be suitable for the size of the conductor required for the
connection. The terminations shall be crimped with the correct crimping tool as per manufacturer’s
recommendations. Washers and spring washers or other approved locking devices shall be used
on all terminations. See Annexure C for the relay specific terminations and maximum number of
connections per terminal.
Cable insulation shall be stripped using the appropriate wire strippers (pliers and side cutters are
not permitted to strip insulation). Each cable core shall have sufficient spare length to allow for
replacement of the crimp lug if required. On completion all crimped terminations shall be subject to
a pull test to check the integrity of the crimp. Refer to NS252 ‘Requirements for wiring within
panels’ for standards on cabinet and panel wiring.
NW000-S0038
Page 12 of 28
Amendment No 0
Figure 9: Recommended crimpable pre-insulated cable terminations
Figure 10: Recommended method of crimping pre insulated cable termination
5.4
Crimping
All lugs shall be crimped with the correct crimping tool for the lug type and size intended to be used
and recommended by the lug manufacturer or as approved for use by Ausgrid. Refer to Figure 10
for correct stripping procedure. A list of manufacturers approved crimpers and the lugs they’re
designed for can be found in Annexure B.
On solid lugs i.e. Utilux Heavy duty the crimp should be made in the middle of the top side of lug to
ensure correct crimping is achieved.
On completing all crimps a visual inspection and pull test shall be carried out to ensure that there is
no movement of the wire inside the ferrule within the crimped connection. The lug shall then be
marked with a marking pen to indicate that it has been checked.
NW000-S0038
Page 13 of 28
Amendment No 0
6.0
RECORDKEEPING
The table below identifies the types of records relating to the process, their storage location and
retention period.
Table 1 – Recordkeeping
Type of Record
Storage Location
Retention Period*
Approved copy of the network
standard
BMS Network sub process Standard –
Company
Unlimited
Draft Copies of the network
standard during
amendment/creation
TRIM Work Folder for Network
Standards (Trim ref. 2014/21250/20)
Unlimited
Working documents (emails,
memos, impact assessment
reports, etc.)
TRIM Work Folder for Network
Standards (Trim ref. 2014/21250/20)
Unlimited
* The following retention periods are subject to change eg if the records are required for legal
matters or legislative changes. Before disposal, retention periods should be checked and
authorised by the Records Manager.
7.0
AUTHORITIES AND RESPONSIBILITIES
For this network standard the authorities and responsibilities of Ausgrid employees and managers
in relation to content, management and document control of this network standard can be obtained
from the Company Procedure (Network) – Production/Review of Network Standards. The
responsibilities of persons for the design or construction work detailed in this network standard are
identified throughout this standard in the context of the requirements to which they apply.
8.0
DOCUMENT CONTROL
Content Coordinator
:
Manager - Secondary Systems
Distribution Coordinator
:
Engineering Information and Services Manager
NW000-S0038
Page 14 of 28
Amendment No 0
Annexure A - Lug Stock codes
Table A1 - Utilux Heavy duty Pre-insulated
Terminal style
Stock code
2.5 sq mm Flat blade 5.1mm hole
74773
2.5 sq mm Right angle narrow blade 4.1mm hole
180036
2.5 sq mm Right angle standard blade 4.1 mm hole
74856
M6 hole
74781
Table A2 - Ring terminals for M4 Relay Bases
Terminal style
Stock code
Red 0.25mm – 1.65mm conductor
181397
Blue 1.04mm – 2.63mm conductor
181398
Table A3 - Battery Trip Links
Terminal style
Stock code
Moulded Battery Trip Links
NW000-S0038
78493
Page 15 of 28
Amendment No 0
Annexure B - Crimping Tools
B1 Usage of crimping tools
The following table is a list of manufacturers approved crimpers for designed lugs. This is meant as
a guide only.
Table B1 - Approved usage of crimp tools
Lug
Crimping Tool
Utilux Heavy Duty Lug
Utilux 120/A1 (Figure B2)
Utilux Split Colour Coded Lugs
Utilux #120 or #102
Utilux Bootlace Ferrule
Utilux #125
Cabac Bootlace Ferrule
Cabac HNKE5 or HNKE4
Cabac Split Colour Coded Lugs
Cabac KTC1 – HP3 or HP3/1 (Figure B1)
B2-Cabac KTC1 crimping tool for colour coded lugs
Figure B1 – Cabac KTC1 crimping tool
NW000-S0038
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Amendment No 0
B3 Utilux 120A/1 crimping tool
Suitable for 1.5, 2.5,4 and 6mm pre-insulated heavy duty lugs
Figure B2 – Utilux 120A/1 crimping tool
NW000-S0038
Page 17 of 28
Amendment No 0
Annexure C - Relay Specific Terminations
C1 Table of relay terminals
Manufacturer
Relay Type
Termination Type
Lug
Max No.
Connections
GE
C70
Screw
Screw and Plate
90° Ring/Blade
Bootlace
2
2
GE
L90
Screw
Screw and Plate
90° Ring/Blade
Bootlace
2
2
GE
T60
Screw
Screw and Plate
90° Ring/Blade
Bootlace
2
2
RMS
2C63K12
Screw
90° Ring
2
RMS
2V164
Screw
90° Ring
2
RMS
3A32KXX
Screw
90° Ring
2
RMS
TR12
Screw
90° Ring
2
Schneider
P142
Screw
90° Ring/Blade
2
Schneider
P545
Screw
90° Ring/Blade
2
SEL
SEL 241101
Screw
Screw and Plate
90° Ring/Blade
Bootlace
2
1
SEL
SEL 2505
Screw and Plate
Bootlace
2
SEL
SEL 2506
Screw and Plate
Bootlace
2
SEL
SEL 25943C3XX
Screw and Plate
Bootlace
2
SEL
SEL 259503C31X
Screw and Plate
Bootlace
2
SEL
SEL 487E
Screw and Plate
Bootlace
2
SEL
SEL 751
Screw
Screw and Plate
90° Ring/Blade
Bootlace
2
1
SEL
SEL 787
Screw
Screw and Plate
90° Ring/Blade
Bootlace
2
1
Siemens
7SD610
Screw and Plate
Bootlace
2
Tekron
ITR D2-3K
Screw and Plate
Bootlace
1
Tekron
TTM01-E T2-TL60NLA
Screw and Plate
Bootlace
1
NW000-S0038
Page 18 of 28
Amendment No 0
C2 Common relay terminals
Figure C1 Typical terminals of a Schneider relay
Figure C2 Typical terminal connections of a Schneider relay
NW000-S0038
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Amendment No 0
Figure C3 Typical terminals of a GE relay
Figure C4 Typical terminal connections of a GE relay
NW000-S0038
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Amendment No 0
Figure C5 Typical terminals of a Siemens relay
Figure C6 Typical terminal connections of a Siemens relay
NW000-S0038
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Amendment No 0
Figure C7 Typical terminals of an SEL relay
Figure C8 Typical terminal connections of a SEL relay
NW000-S0038
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Amendment No 0
Figure C9 Typical terminals of an RMS relay
Figure c10 Typical terminal connections of an RMS relay
NW000-S0038
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Amendment No 0
Figure C11 Typical terminals of a Tekron relay
.
Figure C12 Typical terminal connections of a Tekron relay
NW000-S0038
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Amendment No 0
If two lugs need to be connected to the same terminal, they shall be connected in the following
arrangements.
Figure C13 Back-to-back
Figure C14 On top same way (one straight one right angle)
NW000-S0038
Page 25 of 28
Amendment No 0
Figure C15 On top opposite way
NW000-S0038
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Amendment No 0
Annexure D – Sample Compliance Checklist
NW000-S0038
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NW000-S0038
Amendment No 0
Page 28 of 28

NS253 Termination of Wiring in Substation Protection and

Transcription

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