Engineering Specification TECHNICAL SPECIFICATION FOR AN ESSENTIAL Version: 3 Issued: 14 October 2016 Owner: Chief Engineer Approved By: Andrew Russack Head of Engineering - Electrical PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION
Approval Amendment Record Approval Date Version Description 15/07/2015 1 Initial Issue. Supersedes parts of L1-CHE-SPE-024(1). 11/08/2016 2 Revised to include inrush and efficiency requirements. Tapping, lifting and size requirements clarified. Errors corrected and wording clarified throughout. 14/10/2016 3 Winding vectors revised. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 2 of 15
Table of Contents 1 Purpose... 4 2 Scope... 4 3 Acronyms and Abbreviations... 4 4 Definitions... 4 5 References & Legislation... 5 5.1 Standards... 5 5.2 Latest Issues and Amendments... 5 6 Background... 5 7 General Requirements... 5 8 Operating Conditions... 7 8.1 Service Conditions... 7 8.2 Electrical Conditions... 7 9 Ratings & Configurations... 7 10 Winding Connection... 8 11 Construction... 8 11.1 Transformer Enclosure & Cooling - Dry Type Transformer... 8 11.2 Transformer Cooling and Other Requirements - Oil Type Transformer... 8 11.3 Primary Terminals... 9 11.4 Secondary Terminals... 9 11.5 Earthing Terminal... 9 11.6 Painting... 10 11.7 Lifting Facility... 10 11.8 Size... 10 11.9 Rating Plate... 10 12 Testing... 10 12.1 Type Test... 10 12.2 Routine Tests... 10 12.3 Test Certificates... 10 13 Documentation and Support... 11 13.1 Documentation Requirements... 11 13.2 Design Drawings... 11 13.3 Drawing Format... 11 13.4 Technical Maintenance Plan... 11 13.5 Maintenance Manual... 12 13.6 Installation Instruction Manual... 12 14 Appendices... 13 Appendix A Design Management Requirements... 13 Appendix B Technical Data Schedule Form... 14 PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 3 of 15
1 Purpose This document is the technical specification for an Essential Services Supply Step Up Transformer, for use in MTM substations. 2 Scope This document applies to the supply of a Power Transformer to supply the MTM Essential Services Distribution System or 2.2kV Signal Power Distribution System from a 400V UPS backed supply in a substation installation as part of the MTM Electrical Network. This Transformer may be integral to the UPS assembly, or separately supplied and installed within the substation. 3 Acronyms and Abbreviations AC Alternating Current ACCB Alternating Current Circuit Breaker AS Australian Standard HV High Voltage MTM Metro Trains Melbourne Pty. Ltd. 4 Definitions For all technical terms refer to AS 60076. Essential Services Shall Should Refers to services, apparatus and systems described in L1-CHE-SPE-154. Also refers to the power distribution system supplying these services. Is used as the descriptive word to express a requirement that is mandatory to achieve conformance. Is used as the descriptive word to express a requirement that is recommended in order to achieve compliance. Should can also be used if a requirement is a design goal but not a mandatory requirement. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 4 of 15
5 References & Legislation 5.1 Standards The Transformer shall comply with all relevant Standards, including: AS 60076 AS 1767 AS 2374 Power Transformers Insulating Liquids Specification for Unused Mineral Insulating Oils for Transformers & Switchgear Power Transformers Note: All materials and components shall comply with the relevant Australian Standard or, where these do not exist, with the relevant IEC or EN Standard. 5.2 Latest Issues and Amendments Reference to all standards shall be read as a reference to the latest edition of that standard and amendments available at the time of tendering. 6 Background The Transformer will be used for the purpose of converting power from the 400V output of a dual convertor UPS to the Essential Services Distribution System or Signal Power Distribution System voltage for Essential Services purposes. The Essential Services Distribution System standard is a 3.3kV three phase 50Hz system, in phase with the 22kV system. Other legacy signal power distribution systems exist, including: 2.2kV single phase, 50 Hz, two wire unearthed, in phase with 22kV white-blue phase 1kV three phase, 50 Hz, earthed, leading 22kV system by 30 degrees 650V single phase, 50 Hz, two wire unearthed, in phase with 22kV white-blue phase Due to the varied installations, a scope of works document will detail specific requirements including but not limited to: Secondary Voltage (or equivalent table of ratings to that shown in section 9) Rated Power Indoor or outdoor installation Type of primary and secondary terminals required Oil insulated or dry type The Essential Services Step Up Transformer forms part of the Essential Services Power Supply system, as shown in Figure 1. 7 General Requirements The Transformer shall be designed and manufactured to give the highest level of reliability whilst requiring the minimum level of maintenance under continuous operating conditions. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 5 of 15
22kV Bus 22kV/400V Dyn1 Substation Earth 400V Bus 400V 3 phase UPS Substation L&P 400V Board Static Switch Battery Isolator Synchronisation Logic Battery Bank Manual Bypass Switch Step Up Transformer Essential Services / Signal Switchgear Synchronisation Signal Synchronisation Signal Figure 1: UPS System Interconnections PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 6 of 15
8 Operating Conditions 8.1 Service Conditions The service conditions in AS 60076 shall be applied except that the maximum ambient temperature shall be taken as 45 C. The air may be slightly polluted by dust. Transformers designated for indoor installation will be mounted on a concrete floor inside a substation building or suitable annex. Transformers designated for outdoor installation will be mounted on a concrete slab, unprotected from the weather. 8.2 Electrical Conditions Supply to the primary winding of the Transformer will be taken via a circuit breaker or fuse from a 400V 3 phase 50Hz supply. The secondary winding will be connected to an ACCB forming part of an Essential Services Switchgear Assembly. The transformer may be subject to significantly unbalanced load, including no load on one phase at all. 9 Ratings & Configurations This specification covers the Essential Services Distribution System and 2.2kV signal power distribution system. The specific ratings and characteristics of each of these are listed in the table below: Type 2.2kV 3.3kV Phases 3 3 Rated Primary Voltage 400V 400V Rated Secondary Voltage 2200V 3300V Standard Values of Rated Power (specified at the time of purchase) 60kVA 120kVA 180kVA 60kVA 120kVA 180kVA Rated Frequency 50Hz 50Hz Primary winding highest voltage for equipment <1.1kV <1.1kV Secondary winding highest voltage for equipment 3.6kV 3.6kV Rated Primary short-duration power frequency withstand voltage 10kV RMS 10kV RMS Rated Primary lightning impulse withstand voltage 20kV peak 20kV peak Rated Secondary short-duration power frequency withstand voltage 10kV RMS 10kV RMS Rated Secondary lightning impulse withstand voltage 20kV peak 20kV peak Earthing of Secondary Unearthed TBA Maximum Sound Power Level Reduced Reduced Level Level Winding Vector (Secondary/HV winding in upper case, Primary/LV in lower case) YNd11 YNd11 Regulation @ 0.6 pf 5% 5% Percentage Impedance 4% 4% Maximum Inrush 8x I r 8x I r Minimum Power Efficiency (in accordance with AS 2374.1.2) 97% 97% PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 7 of 15
10 Winding Connection Five taps on the secondary (HV) windings shall be provided for the following range: +5.0%; +2.5%; 0%; -2.5%; -5.0%. Alternative tapping arrangements may be considered if suitable for the particular installation and approved by the Head of Engineering Electrical. The selection of the tapping shall be off-load. The tap changing device shall have a continuous rating of 100% of the Transformer full load current. For oil type transformers, the tap position shall be selected by a robustly constructed, external, pad-lockable, manually operated, spring-loaded selector switch, suitable for operation by hand without the use of special tools. The switch positions shall be labelled. For dry type transformers, the tap position may be selected either as described above, or by moveable connection links located on each of the primary windings. Each of these links shall be constructed from a single section of suitable conductor and shall be capable of making all tap settings. The tap links shall be located behind a securely bolted panel. 11 Construction 11.1 Transformer Enclosure & Cooling - Dry Type Transformer The Transformer shall be enclosed by a ventilated metallic enclosure cooled by naturally circulated external air. The enclosure should be suitable for indoor or outdoor installation, unless integral to the UPS in which case it may be suitable for indoor installation only. The transformer shall be naturally cooled - it shall be Class AN. The enclosure shall provide a minimum ingress protection of IP 21 for indoor installations, or IP 43 for outdoor installations, in accordance with AS 60529. 11.2 Transformer Cooling and Other Requirements - Oil Type Transformer The oil preservation system can be freely breathing or sealed type. The transformer shall be naturally cooled (ONAN). The insulating oil shall comply with AS 60076 and shall not contain any Polychlorinated Biphenyl (PCB). An oil test for PCB content shall be performed by an independent NATA certified laboratory, and the test results provided to MTM prior to delivery. A concentration of PCB greater than one part per million will result in rejection of the transformer. The transformer shall be equipped with the standard fittings as described below: Oil gauge Drain valve 25mm nominal bore pipe thread with flanged plug Oil filling hole and cap Breathing device of weatherproof type, which may also be used as a filling hole Thermometer pocket Where a fully sealed transformer is offered the oil gauge and thermometer pocket need not be included. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 8 of 15
11.3 Primary Terminals The primary terminals shall be one of three configurations as outlined in the table below: Configuration Primary Enclosed Requirements An accessible air insulated cable box shall be provided, suitable for the connection of an insulated cable rising from below. The cable may be up to 50mm 2 of the copper insulated type and will be terminated with appropriate lugs for connection to the bushings. If required, appropriate cable supports shall be provided within the enclosure such that the weight of the output cable is not taken by the electrical connections. Primary Direct Termination For dry type transformers only, the secondary cable shall be terminated directly onto the windings. Appropriate cable supports shall be provided within the enclosure such that the weight of the output cable is not taken by the electrical connections 11.4 Secondary Terminals The secondary terminals shall be located on the opposite side of the transformer enclosure to the primary terminals. The terminals shall be suitable for directly connecting to appropriately terminated LV cables, suitably sized for the rating of the transformer. The secondary terminals shall be one of three configurations as outlined in the table below: Configuration Secondary Enclosed Secondary Direct Termination Requirements An accessible air insulated cable box shall be provided, suitable for the connection of an insulated cable rising from below. The cable may be up to 50mm 2 of the copper insulated type and will be terminated with appropriate lugs for connection to the bushings. If required, appropriate cable supports shall be provided within the enclosure such that the weight of the output cable is not taken by the electrical connections. For dry type transformers only, the secondary cable shall be terminated directly onto the windings. Appropriate cable supports shall be provided within the enclosure such that the weight of the output cable is not taken by the electrical connections 11.5 Earthing Terminal The transformer frame shall be directly connected to the substation earth. Two pre-drilled M12 holes shall be provided on opposite sides of the transformer for this purpose. Each enclosure door (where fitted) shall be adequately connected to the main enclosure by copper earth braids, one located at the top and the other at the bottom of each door. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 9 of 15
11.6 Painting Dry type transformer - The enclosure shall be properly prepared and painted so as to be suitable for outdoor installation irrespective of designated installation location. Oil Insulated Transformer - The transformers external tank shall be properly prepared and hot dip galvanised. The final colour coat shall be light grey as described by AS 2700S:2011 (N35), and the transformer shall be supplied with touch-up paint. 11.7 Lifting Facility 11.8 Size The Transformer shall be fitted with a facility for lifting and moving by both a crane and a forklift. The transformer and enclosure shall be as compact as possible.. 11.9 Rating Plate The Transformer Rating Plate shall comply with the requirements of AS 60076. The tap link connections and positions or tap changer positions shall be clearly shown on the rating plate The rating plate shall be constructed of stainless steel and shall be securely riveted to the body of the transformer. Recorded information shall be physically etched, embossed or engraved clearly onto the surface of the rating plate and shall be highlighted with black paint. 12 Testing 12.1 Type Test A Type Test Certificate from a design which is representative of the Transformer to be supplied shall be provided with the Tender documentation. 12.2 Routine Tests All routine tests as described in Clause 10 of AS 60076.1:2005 shall be performed on the Transformer at the manufacturer s factory. MTM reserves the right to appoint a representative to witness these tests. Seven working days notification shall be given to MTM of intention to carry out factory testing. 12.3 Test Certificates The results of all tests shall be recorded on test certificates. The test certificates shall clearly show the performance of the equipment and shall be accompanied by tables showing the actually measured values and all calculations. The test certificates shall be forwarded to MTM and the results approved by MTM prior to delivery. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 10 of 15
13 Documentation and Support 13.1 Documentation Requirements All documentation shall be provided in English. One electronic and eight paper copies of the each document shall be provided and the content shall be identical in each copy. Every page of the documentation shall be clearly identified in relation to the document to which it belongs and the version of that document. All pages of multi-page documents shall be uniquely numbered. It shall be possible to readily determine if all pages of a document are present. Manuals shall be A4 size and shall be bound in durable covers or in 4-D ring binders. 13.2 Design Drawings The following drawings must be supplied: Construction details of the Transformer including dimensions. Physical layout and arrangement of the components of the Transformer. Mounting requirements for the Transformer. Physical layout and arrangement of the primary and secondary terminals. Drawings of the Transformer Rating Plate and data All other drawings required for Installation, Testing, Commissioning, Operation and Maintenance 13.3 Drawing Format All drawings must comply with the PTV Infrastructure Drafting Standard and shall be submitted for MTM approval prior to manufacturing. Files shall be provided in Microstation format on compact disk (CD). 13.4 Technical Maintenance Plan A Technical Maintenance Plan which establishes the maintenance policy for the Transformer recommended by the supplier shall be provided. This shall detail the preventative servicing schedules and maintenance intervals and latitudes for all components and systems of the Transformer. The servicing schedules shall reference appropriate detailed instructions in the maintenance manual. The Technical Maintenance Plan shall contain a list of any recommended spare parts, detailing price, supplier and procurement lead-times. The Technical Maintenance Plan shall detail safe disposal procedures applicable for when the Transformer is no longer serviceable (recycling, hazardous waste etc.). PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 11 of 15
13.5 Maintenance Manual The Maintenance Manual shall detail: All of the servicing activities. Any overhaul instructions. The adjustment procedures. The changing of components for repairs, and Fault-finding procedures. Spares support schedule The Maintenance Manual shall also include a complete set of as-built drawings and a comprehensive parts list for the Transformer. 13.6 Installation Instruction Manual An Installation Instruction Manual shall be provided and shall contain instructions which will enable the Transformer to be properly installed, tested and commissioned. This shall include all necessary drawings. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 12 of 15
14 Appendices Appendix A Design Management Requirements This appendix describes the documentation which should be provided as a minimum at each stage of the procurement process. The documentation shall comply with the specifications above. Tender Submission The following documents shall be provided as part of the tender submission: General Arrangement drawing of the Transformer which clearly shows: The overall dimensions of the Transformer and details of the enclosure Details of the proposed primary terminations Details of the proposed secondary terminations Type Test Certificates The Technical Data Schedule in Appendix B filled in. Contract Documentation One set of PDF copies of the drawings and documentation as described in Clauses 13.2 and 13.6 and any additional documentation detailing the design should be provided for review and approval by MTM four weeks after the Contact Award Date. No manufacture shall commence until the drawings have been approved. An allowance of five working days should be made by the supplier for the review and approval of submitted drawings Pre-Delivery Documentation As part of the deliverables, the supplier shall provide five hard copies of the following documents: Technical Maintenance Plan Installation Instruction Manual Maintenance Manual Storage, handling, loading and off-loading instructions Test results Approved drawings as listed in 13.2 In addition, the supplier shall provide copies of the As Built layouts and Schematic drawings in electronic format (PDF and Microstation) PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 13 of 15
Appendix B Technical Data Schedule Form The Tenderer shall supply the following information and guaranteed performance thereof. Compliance Does the Transformer fully comply with this specification? Yes No Is a Type Test Certificate attached? Yes No Is a general arrangement sketch attached? Yes No Type Oil Dry Winding Vector Rated Power Primary winding (kva) Rated Voltage Primary windings (V) Secondary windings (V) Rated Current Primary windings (A) Secondary windings (A) Inrush current (A) Rated Insulation Level Primary Power Frequency Withstand Voltage (kv) Primary Impulse Withstand Voltage (kv) Secondary Power Frequency Withstand Voltage (kv) Secondary Impulse Withstand Voltage (kv) Impedance & Regulation Percentage Impedance at Rated Primary Power (%) Regulation at 0.6 power factor Losses Iron Loss (at Rated Primary Voltage) (W) Copper Loss (at Rated Primary Current) (W) Power Efficiency at 50% load and unity power factor (%) Tap Changer Manufacturer Type Voltage Rating (V) Current Rating (A) PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 14 of 15
Oil Type only Volume of Oil (L) Is the Transformer freely breathing? Yes No Is a Conservator fitted? Yes No Is the Transformer a sealed-tank system with gas cushion? Yes No Is the Transformer a sealed, completely filled system? Yes No Tank or Enclosure Thickness (mm)... Enclosure Overall Length (mm) Overall Width (mm) Overall Depth (mm) Enclosure material Enclosure thickness (mm) Enclosure finish / colour Weight Mass of Core and Windings (kg) Total mass (kg) Primary Terminals Manufacturer Type Voltage Rating (V) Current Rating (A) Height above base of enclosure (mm) Cable box dimensions (if applicable) (mm) width (mm) depth (mm) height Secondary Terminals Manufacturer Type Voltage Rating (V) Current Rating (A) Height above base of enclosure (mm) Cable box dimensions (if applicable) (mm) width (mm) depth (mm) height PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 15 of 15