Engineering Specification Electrical Networks TECHNICAL SPECIFICATION FOR A 1500V DC RECTIFIER Version: 3 Issued: February 2018 Owner: Head of Engineering - Electrical 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 5/02/2016 1 Initial issue under MTM. 26/09/2016 2 Amended to reflect change of duty class. Corrections throughout 05/02/2018 3 Title simplified. Addition of handrails and ladder brackets allowing work on top of transformer. Documentation and support section revised. Appendix B removed. Clarifications and simplifications throughout. Also supersedes MESP 020100-01. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 2 of 23
Table of Contents 1. 2. 3. 4. 5. Purpose... 5 Scope... 5 Abbreviations... 5 Definitions... 5 References & Legislation... 5 5.1 5.2 Standards... 5 Latest Issues and Amendments... 6 6. 7. 8. 9. Background... 6 General Requirements... 7 Ratings... 8 Operating Conditions... 9 9.1 Electrical Conditions... 9 10. 11. Winding Connection... 9 Construction... 10 11.1 11.2 11.3 11.4 11.5 11.6 11.7 11.8 11.9 11.10 Transformer Enclosure Oil-Immersed Type... 10 Transformer Enclosure - Dry Type... 10 Cooling... 10 Primary Terminals... 11 Secondary Terminals... 12 Earthing Terminals... 13 Lifting Facilities... 13 Size... 13 Rating Plate... 13 Temperature Indicating Scheme... 13 12. Requirements for Oil-Immersed Type... 14 12.1 12.2 12.3 12.4 12.5 12.6 12.7 12.8 12.9 12.10 Insulating Oil... 14 Cooling Fins... 14 Fittings and Accessories... 14 Hand-holes in Top Cover... 14 Sampling Valve... 14 Pressure Relief System... 14 Oil Filling Hole and Cap... 14 Drain Valve... 15 Dehydrating Breather... 15 Oil Leaks... 15 13. Testing... 15 PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 3 of 23
13.1 Type Test... 15 13.2 Routine Tests... 15 13.3 Test Certificates... 16 13.4 Short-Circuit Tests... 16 14. Documentation and Support... 16 14.1 Contract Documentation... 16 14.2 Design Documentation... 16 14.3 Delivery Documentation... 17 14.4 Design Drawings... 17 14.5 Technical Maintenance Plan... 17 14.6 Maintenance Manual... 18 14.7 Installation Instruction Manual... 18 14.8 Operating Instructions Manual... 18 14.9 Tools & Equipment... 18 14.10 Documentation Requirements... 18 14.11 Drawing Format... 18 Appendix A Technical Data Schedule Form... 19 PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 4 of 23
1. Purpose This document is the technical specification for a dry or oil-immersed type Rectifier Transformer suitable for use in the MTM 1500V DC traction system. 2. Scope This document applies to the supply of a 2.5MW or 4 MW Rectifier Transformer for use in new and existing substations as part of the MTM Electrical Network. It shall also be applied in the case of renewals of existing installations unless prevented by particular site requirements. This specification is applicable to both oil-immersed and dry type transformers. This specification is to be read in conjunction with the supplied Scope of Works document, which details exact quantities and any other special requirements. 3. Abbreviations ACCB - Alternating Current Circuit Breaker DCCB - Direct Current Circuit Breaker Electrol - Electrical Systems Control Centre MTM - Metro Trains Melbourne 4. Definitions For all technical terms refer to AS 60076 and IEC 62695. Shall Should Is used as the descriptive word to express a requirement that is mandatory to achieve conformance to the standard. Is used as the descriptive word to express a requirement that is recommended in order to achieve compliance to the standard. should can also be used if a requirement is a design goal but not a mandatory requirement. 5. 5.1 References & Legislation Standards The Rectifier Transformer shall comply with all relevant Standards, including but not limited to: IEC 62695: 2014 AS 60076 Railway Applications Fixed Installations Traction Transformers Power Transformers (All Parts) Note: All materials and components shall comply with the relevant Australian Standards or, where these do not exist, with the relevant IEC or EN Standard. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 5 of 23
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 Rectifier Transformer covered by this document will be used in MTM Traction Substations. These Substations primarily convert electricity from high voltage AC to 1500V DC power for the MTM Electric Train System. The Rectifier Transformer is one part of the Substation Rectifier Unit which consists of the Rectifier ACCB, Rectifier Transformer, Rectifier Assembly, Rectifier Unit Control and Protection System and Rectifier DCCB or Isolator as illustrated below. The Transformer designed to this specification is intended to be directly connected to a Rectifier Assembly complying with MESP 020200-02 Technical Specification for a 4MW Rectifier Assembly for the 1500V DC Traction System. Rectifier Unit Rectifier ACCB Rectifier Transformer Rectifier Assembly Rectifier DCCB or Isolator Control & Protection System for 1500V DC Rectifier Unit Local Control Panel RTU Substation Battery (Control Supply) SCADA System Electrical Systems Control Centre There are a number of possible configurations based on requirements of the particular installation and so the primary voltage, power rating and requirement for indoor or outdoor installation will be specified in a separate scope of works document. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 6 of 23
7. General Requirements The Rectifier Transformer shall be designed and manufactured to give the highest level of reliability whilst requiring the minimum level of maintenance under continuous operating conditions and shall have a minimum design life of 30 years. The conditions under which the life span is based shall be stated. The transformer shall not contain any asbestos containing materials. A certificate which states that the equipment is free of asbestos containing material shall be provided, prior to delivery. The Rectifier Transformer may be of either the dry or oil-immersed type unless specified in the scope of works. The location of the secondary phase arrangement shall be such that no crossing over of the secondary cables between the rectifier transformer and rectifier assembly occurs. The configuration described in section 11.5 may be altered if specified in the scope of works. The rectifier transformer shall meet all relevant environmental Acts, Legislation and Regulations, Codes of Practice and Standards, and shall be designed to minimise the impact on the environment. Accordingly the design of the Rectifier Transformer will minimise its environmental impact over its entire asset life cycle, including construction, ongoing operation and disposal. In particular, MTM has a focus on reduced electrical losses in its substation equipment. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 7 of 23
8. Ratings The rectifier transformer shall be nominally 2.5MW or 4MW, and either 11kV or 22kV, with the appropriate size to be nominated based on power modelling undertaken in accordance with MTM requirements and MEST 000002-06 Principles and Performance. The nominal rating and voltage of the transformer shall be specified at the time of ordering in a scope of works document. The Rectifier Transformer shall comply with the following specifications in accordance with IEC 62695: Rating Value 2.5MW 11kV 4MW 11kV 2.5MW 22kV 4MW 22kV Primary Nominal Voltage (U NL ) 11,000V 11,000V 22,000V 22,000V Primary Voltage Range +10/-6 % Basic Power of the Transformer (SBGL) 4,235 kva Secondary Nominal Voltage (U vo ) 581 V Nominal Frequency ( +/- 0.5 Hz) (f N ) 50 Hz Duty Class - as per IEC 62695 Annex A Class IXA Winding Vector Dd0y11 Primary Rated AC Withstand Voltage 28 kv rms 50 kv rms Primary Rated Lightning Impulse Withstand 95 kv peak 150 kv peak Secondary Rated AC Withstand Voltage 10 kv rms Secondary Rated Lightning Impulse Withstand 20 kv peak Rated short circuit current (I dn ) 10 times Basic Current 8.33 times Basic Current 10 times Basic Current 8.33 times Basic Current Rated short circuit current duration 200 ms Rated impedance voltage at basic power (z P/S ) 10% 12% 10% 12% Total direct voltage regulation (U dtn ) 5% Maximum Sound Power Level Reduced level (AS 60076.10:2009) Coupling Factor (K) 0.9 PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 8 of 23
9. 9.1 Operating Conditions The standard operating conditions in AS 60076 shall be applied with the exception that the ambient temperature shall be taken as 45 C. The air may be slightly polluted by dust. Electrical Conditions Supply to the primary winding of the rectifier transformer will be taken directly via a distribution company supply feeder or via an internal MTM distribution feeder. The HV supply will be either 11 or 22 kv (as specified), 3 phase 50 Hz. It shall be considered as non-effectively earthed. The secondary winding will be connected to the rectifier assembly and then to the 1500 V DC railway traction overhead wiring network (which is susceptible to surges and short circuits typical of this type of system) via high speed DCCBs. The transformer shall be able to withstand stresses as applied by a short circuit on the supply side of 500MVA (at 22kV) or 350MVA (at 11kV). 10. Winding Connection The windings shall be connected in accordance with Connection No. 12 of Table C.1 in IEC 62695. The two secondary windings shall be of equal power rating. The following output tappings on the primary windings shall be provided as a minimum: +6%, +4%, +2%, 0%, -2%, -4%, -6%. If specified at the time of purchase, the following additional tappings shall be provided: -8%, -10%, -12%, -14%, -16%. The selection of the tapping shall be off-load. For oil-immersed type transformers: The tap-changing device shall have a continuous rating of 300% of the transformer full load current. The tap position shall be selected by an external, pad lockable, manually operated spring-loaded selector switch. The tap-changing switch shall be of robust construction, and shall be suitable for manual operation by hand without the use of any special tools. The switch positions shall be labelled and shall be readable from the ground. For dry type transformers, the tapping selection may be as described for oil-immersed type transformers, or: The tap shall be selected by moveable connection links. Links shall be located on each of the primary windings. Each link shall be constructed from a single section of suitable conductor, and shall be capable of making all tap settings (refer 10.3). The links shall be easily accessible from ground level without the use of a ladder, and shall be located behind a securely bolted panel. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 9 of 23
11. Construction 11.1 Transformer Enclosure Oil-Immersed Type The housing for an oil-immersed transformer shall be manufactured from mild steel or other suitable material. The enclosure shall be properly prepared and painted so as to be suitable for outdoor installation. The final colour coat shall be light grey as described by AS 2700S:2011 (N35). The preparation shall comply with AS 1627. Mild steel transformer enclosures shall be suitably galvanised prior to painting or powder coating. The enclosure shall not have any sharp contours or corners, which are liable to cause injury. A pressure-can of touch-up paint in the same colour and tint as the transformer shall be supplied along with the transformer. Transformers without aerial primary bushings shall be suitable for two persons to stand and work on top of the enclosure. Guardrails compliant with AS 1657 shall be provided, along with one or more ladder brackets. It shall be possible to safely work on the low voltage terminations without the use of additional scaffolding or work platforms. 11.2 Transformer Enclosure - Dry Type The transformer shall be enclosed by a ventilated metal enclosure. 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. The enclosure may be fabricated from mild steel, stainless steel or any other suitable material. The enclosure shall be properly prepared and painted so as to be suitable for outdoor installation. The final colour coat shall be light grey as described by AS 2700S:2011 (N35). The preparation shall comply with AS 1627. Mild steel transformer enclosures shall be suitably galvanised prior to painting or powder coating. The enclosure shall not have any sharp contours or corners, which are liable to cause injury. A pressure-can of touch-up paint in the same colour and tint as the transformer shall be supplied along with the transformer. Removable panels which are securely bolted shall be provided on the HV and LV sides of the transformer. Transformers without aerial primary bushings shall be suitable for two persons to stand and work on top of the enclosure. Guardrails compliant with AS 1657 shall be provided, along with one or more ladder brackets. It shall be possible to safely work on the low voltage terminations without the use of additional scaffolding or work platforms. 11.3 Cooling The transformer can be either oil-immersed or dry type. It shall be naturally cooled; Class AN for dry type and ONAN for oil immersed type. The transformer shall not require any special forced ventilation systems. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 10 of 23
11.4 Primary Terminals The terminals of the primary and secondary windings shall be located on opposite sides of the Transformer. The transformer primary terminals shall be one of the options listed below. The exact type and specific arrangement required will be specified in the Scope of Works document. Aerial Bushings Separable, Dead-Break Bushing Wells Unenclosed terminals shall be provided on top of the transformer, and shall allow for connection of uninsulated aerial cables to the primary windings. The bushings shall be mounted and assembled in accordance with best practice. All external surfaces and gaskets shall be suitably sealed against the weather. Bushing terminals shall be provided with cable fittings capable of providing secure mechanical and electrical connection to high conductivity bare copper aerial conductors. Typical conductor size ranges between 70 and 100mm 2 cross section, dependent on the installation. The HV bushings shall be constructed of a suitable polymeric material. The minimum clearance between phase and earth and between phases shall be as defined in AS 2067. The minimum safety clearance height to the base of the Primary Bushings shall be 2500mm. Suitable anti vermin insulating covers shall be provided over the bushings. Separable, dead-break bushing wells shall be provided to enable high voltage cable connection to the transformer via suitable plug inserts. The cones should be type C in accordance with EN50181. The bushing wells shall be suitable for the connection of insulated cables coming from either below the Transformer. The standard cables used are described in MESP 012000-01 and MESP 012000-02. The terminals shall be located at a suitable height to allow for the easy termination of cables and disconnection of the plug inserts without use of an elevated work platform or similar. Appropriate cable supports shall be provided such that the weight of the input cable is not taken by the electrical connections. All clearances are to meet the requirements of AS 2067 PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 11 of 23
Air Insulated Termination Directly onto High Voltage Windings (Dry Type only) If required because of restricted space, enclosed air insulated terminals may be used within the enclosure of a dry type transformer for the connection of high voltage cables either directly to the transformer primary windings or another suitable point within the transformer enclosure. The scope of works will specify if this type of termination will be used. The primary terminals shall be located behind a securely bolted panel. The location of the terminals within the enclosure shall be at least 400mm from the cable entry point to allow for the unscreened length of a typical high voltage cable termination. A non-ferrous gland plate shall be provided where cables enter the transformer enclosure. The standard insulated cables used are described in MESP 012000-01 and MESP 012000-02. All live terminals shall be insulated with a suitably rated heat shrink or equivalent product to ensure the required clearances are met All clearances shall be as required in AS 2067. 11.5 Secondary Terminals The secondary terminals shall be located in a row on top of and parallel to the major axis of the transformer. They shall be arranged, from left to right, facing the transformer from the secondary terminal side in the order 1, 3, 5, 2, 4, 6 corresponding to the numbers shown for Connection No. 12 in Table C1 of IEC 62695. However, if an alternative arrangement is required this will be specified in the scope of work. The secondary terminals shall be enclosed in an air insulated metal enclosure located appropriately to allow aerial cable connection to the rectifier. A non-ferrous gland plate shall be provided. Each terminal shall be capable of connection to six 500mm 2 cables fitted with lugs as shown in Figure 1. 14mmØ >70mm 20mm 50mm Figure 1: Cable Lug PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 12 of 23
The minimum separation distance between terminals and gland plate shall be 300mm to accommodate the cable lugs. The minimum clearance phase to phase and phase to earth shall be not less than 200mm. 11.6 11.7 11.8 11.9 11.10 Earthing Terminals Two 12mm diameter earthing studs or bolts suitable for the attachment of an earthing conductor shall be placed in convenient and easily accessible positions on opposite sides of the bottom of the transformer enclosure. The preferred location of earthing terminals is on the side of the transformer tank or enclosure, within 100mm of the base. Lifting Facilities Suitable lifting lugs shall be provided for lifting the entire transformer with a crane. The base shall be fitted with two channel sections with minimum dimensions of 300mm x 150mm suitable for lifting the Transformer with a forklift. Oil-immersed transformers shall be able to be lifted entirely by a crane without the need to remove oil conservators (if fitted) or any other ancillary equipment Size The transformer, including cooling fins if installed, shall be as compact as possible, and shall occupy a minimal floor space. Any particular restrictions on the size of the transformer will be specified in the scope of works. Rating Plate The Transformer Rating Plate shall comply with the requirements of AS 60076. In addition the information specified in Clause 5.8 of IEC 62695 shall be provided on the rating plate The tap link connections and 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. Temperature Indicating Scheme The manufacturer shall provide a scheme to monitor the temperature of the transformer with the following functionality: Measure winding hot spot temperature on each winding. Measure top oil temperature for oil-immersed type. Provision of a local winding hot spot temperature visual indicator. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 13 of 23
Provision of two sets of contacts for the top oil (if oil-immersed type transformer) and hot spot winding temperature, one set for indication contacts which will be used to provide remote alarms of abnormal temperatures and that the second set of contacts will be set to operate at a higher temperature and will be used to trip the transformer AC circuit breaker. The temperature at which each set of indication contacts operate shall be independently adjustable without the need for additional set up instruments. The manufacturer is to stipulate the most suitable positions for the sensors. Sufficient data shall be made available to enable trending of temperatures to monitor the health of each winding. Logging information to indicate when the system has tripped or alarmed. Analogue values shall be input to a 4-20 milliamp current loop, which shall then allow connection to the RTU. Alternatively, this information may be provided over RS485 using DNP3.0. 12. 12.1 12.2 12.3 12.4 12.5 12.6 12.7 Requirements for Oil-Immersed Type Insulating Oil The insulating oil shall comply with AS 1767, 1999 and shall not be contaminated by any Polychlorinated Biphenyl (PCB). Cooling Fins The cooling fins shall be properly prepared and then hot dipped galvanized to protect them from corrosion. Fittings and Accessories The fittings for filling, draining and monitoring the level of the oil shall be readily available and standard fittings with the following additional fittings and/or modifications: Hand-holes in Top Cover Hand-holes shall be provided and arranged to permit the adjustment of the winding clamps and the replacement of all bushings without removing the top cover. Sampling Valve An oil sampling valve shall be provided at the lowest point of the tank. Pressure Relief System A pressure relief system shall be provided and directed towards the ground close to the transformer. Oil Filling Hole and Cap A 50mm diameter oil filling hole and cap shall be provided on the conservator. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 14 of 23
12.8 12.9 12.10 Drain Valve A 50 mm diameter drain valve with a male outlet and cap shall be provided. The valve and cap shall be lockable with a padlock. Dehydrating Breather The oil preservation system shall be freely breathing. A dehydrating breather shall be provided for fitting after installation. The oil preservation system shall be sealed with a threaded cap prior to despatch from the manufacturing works. The oil conservator (if fitted) shall be fitted with an oil level indicator. Oil Leaks The transformer manufacturer shall guarantee that the transformer will not leak oil for a period of at least 5 years from the date of manufacture as stamped on the rating plate. 13. 13.1 13.2 Testing Type Test Type Tests in accordance with AS 60076.1 (oil-immersed) or AS 60076.11 (dry type) for the 4MW rectifier transformer shall be performed and a certified test certificate showing the test setups and relevant data shall be provided. The temperature rise tests shall be carried out in accordance with Clause 5.2 of IEC 62695. Routine Tests The following tests shall be performed on the transformer at the manufacturer s factory : Routine tests as described in AS 60076.1 (oil type) or AS 60076.11 (dry type) Transformer Sound Level tests as described by AS 60076. Partial Discharge tests as described in AS 60076. Insulated Oil Tests A test shall be performed on each manufactured transformer containing insulating oil by an independent NATA certified laboratory to determine that the Transformer does not contain any Polychlorinated Biphenyl (PCB).A concentration level greater than one part per million will result in the transformer being rejected. The results of the tests shall be available before delivery 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. The tolerances for no load and load losses, voltage ratio and short circuit impedance shall be as specified in IEC 62695. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 15 of 23
13.3 13.4 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. Short-Circuit Tests The following short circuit tests may be requested in the factory or after installation: Four (4) short-circuits cleared by a high speed DCCB One (1) short-circuits applied between the 1500V positive and negative terminals of the Rectifier Assembly, cleared by the Rectifier ACCB with the protection equipment set to clear the short circuit in 200ms. MTM will give the supplier seven working days notice of their intention to carry out these tests. 14. 14.1 14.2 Documentation and Support Contract Documentation One set of PDF copies of the drawings and documentation described in sections 14.4 and 14.7 should be provided for review and approval by MTM approximately 4 weeks after the contract award date. No manufacture shall commence until the drawings have been approved. An allowance of ten working days should be made by the supplier for the review of submitted drawings Design Documentation A hard copy and a soft copy of the following documentation shall be provided to MTM for every design of switchgear cubicle produced at the conclusion of design, and prior to delivery of the switchgear: Technical Maintenance Plan Maintenance Manual Installation Instruction Manual Operating Instruction Manual Storage, handling, loading and off-loading instructions Approved drawings Whenever a design change is made, new copies of the updated design documentation shall be provided to MTM. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 16 of 23
14.3 14.4 Delivery Documentation Each delivery shall include a hard copy of the following documents: Technical Maintenance Plan Maintenance Manual Installation Instruction Manual Operating Instruction Manual Storage, handling, loading and off-loading instructions Test Certificates Approved drawings In addition, a soft copy of the test certificates shall be forwarded to MTM. Design Drawings The drawings described in the table below shall be provided to MTM at the nominated design stages for review, and at the completion of design. Drawing Construction details of the transformer including dimensions and details of the primary and secondary terminations. Concept / Tender Preliminary Design Detailed Design Transformer nameplate Control circuit / wiring diagrams of the temperature monitoring facilities and details of terminations All other drawings required for Installation, Testing, Commissioning, Operation and Maintenance 14.5 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 for all components 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 spare parts, suppliers, indicative pricing, lead times and recommended spares holdings. 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 17 of 23
14.6 14.7 14.8 14.9 14.10 14.11 Maintenance Manual A Maintenance Manual shall be provided which shall detail: The theory of operation of the equipment. All servicing activities. Overhaul instructions. The changing of components for repairs. Fault-finding procedures. The spares support schedule. The maintenance manual shall also include a complete set of as-built drawings and a comprehensive parts list for the transformer. Installation Instruction Manual An Installation Instruction Manual shall be provided The instructions shall enable the transformer to be properly installed, tested and commissioned. This shall include all necessary drawings. Operating Instructions Manual An Operating Instruction Manual shall be provided which shall clearly describe the required procedures for physically operating all of the components of the Transformer. The operating procedures shall be consistent with MTM s requirements. Tools & Equipment Any special tools or other equipment necessary to operate or maintain the transformer shall be provided with each transformer. Any special lifting and installation equipment shall be supplied with the transformer. Documentation Requirements All documentation shall be provided in English. 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. Electronic copies of the Maintenance Manual, Installation Instructions Manual and Operating Instructions shall be provided in both PDF and Microsoft Word formats. Drawing Format All drawings shall comply with PTV Infrastructure Drafting Standard and shall be submitted for MTM approval prior to manufacturing. Drawings shall be provided in Microstation format and PDF. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 18 of 23
Appendix A Technical Data Schedule Form The Tenderer shall supply the following information and guaranteed performance thereof. General Manufacturer Country of Manufacture Type of Primary Terminals Part Number Does the Transformer meet Duty Class IXA (IEC 62695) Is the Transformer oil immersed or dry type? Is the Transformer freely breathing? Is a conservator fitted? Aerial / Dead-Break Bushing Wells / Direct Yes/No Oil-immersed / Dry type Yes/No Yes/No Volume of oil (if applicable) (L) Maximum sound level (db) Compliance Does the Rectifier Transformer fully comply with this specification? Is a Type Test Certificate including Temperature Rise Testing attached? Is a general arrangement drawing attached? Yes/No This Design / Representative Design / No Yes/No Will a certificate be attached to each transformer guaranteeing it does not contain asbestos containing materials? Yes/No Basic Power (Refer IEC 62695) Primary winding (kva) Delta secondary windings (kva) Wye secondary windings (kva) Rated Power (refer IEC 62695) Primary winding (kva) Delta secondary windings (kva) Wye secondary windings (kva) Rated Voltage Primary windings (kv) Delta secondary windings (V) Wye secondary windings (V) PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 19 of 23
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) Rated Current Primary windings (A) Delta secondary windings (A) Wye secondary windings (A) Tap links / Tap Changer (A) Electrical Characteristics Total Direct Voltage Regulation (%) Impedance Voltage at Basic Primary Power Delta secondary short-circuited (%) Wye secondary short-circuited (%) Both secondaries short-circuited (%) Tolerance of impedance (%) Rated Short Circuit Power (Supply Side) Maximum In Rush Current (A) Short Circuit Power Factor Commutating reactance (%) Maximum Coupling Reactance between low voltage windings (%) K Factor Commutative Reactance (%) Maximum Rated Temperature Rise ( C) Windings Tappings (Primary Winding) Resistance of Primary Windings (Ω) at 75 C Resistance of Delta Secondary Winding (Ω) at 75 C Resistance of Wye Secondary Winding (Ω) at 75 C Tolerance of Winding Resistances (%) Winding material (Primary) Winding insulation class (Primary) Insulation materials (Primary) Winding material (Secondaries) Winding insulation class (Secondaries) Insulation material (Secondaries) PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 20 of 23
Losses Iron Loss (at Rated Primary Voltage) (kw) No Load Losses (kw) Tolerance - No Load Losses +/- % Load Losses (at Basic Primary Current) At 25% rated load (kw) At 50% rated load (kw) At 100% rated load (kw) At 150% rated load (kw) Tolerance - Load Losses +/-% Enclosure Overall Length (mm) Overall Width (mm) Overall Height (mm) Enclosure material Enclosure Thickness (mm) Enclosure External Finish Terminal Details Primary Terminals Manufacturer Type Voltage Rating (kv) Current Rating (A) Type of HV Termination Method Dead Break Elbow Manufacturer and Part Number Phase to Phase Clearance of HV Termination Method (mm) Phase to Earth Clearance of HV Termination Method (mm) Secondary Terminals Manufacturer Type Voltage Rating (kv) Current Rating (A) PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 21 of 23
Weight Core and Windings (kg) Oil (if applicable) (kg) Enclosure (kg) Total Weight (kg) Testing Are the following tests included? Routine tests as described in AS 60076.1 OR AS 60076.11 Yes/No Testing as specified in IEC 62695, including temperature rise Yes/No Transformer Sound Level tests as described by AS 60076. Yes/No Partial Discharge tests as described in AS 60076 Yes/No Insulating Oil Tests Yes/No Temperature Monitoring Has a temperature monitoring scheme been provided? Are details of the transducers and relays attached? Yes/No Yes/No PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 22 of 23
Whole of Life Costs List recommended spares and cost Item. Item.. Item. Cost of special tools Item. Item.. Item. Lifetime of equipment. Years Conditions on which the life span is determined.......... Mean Time Between Failures Years Justification or calculation of MTBF (or provide attachment).......... PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 23 of 23