Approval Amendment Record Approval Date Version Description 03/05/2017 1 Initial issue PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 1 of 13
Table of Contents 1. Purpose... 3 2. Scope... 3 3. Abbreviations... 3 4. Definitions... 3 5. References & Legislation... 3 5.1 Standards... 3 5.2 Latest Issues and Amendments... 3 6. Background... 4 7 General Requirements... 4 8. Operating Conditions... 4 8.1 Service Conditions... 4 8.2 Electrical Conditions... 4 9. Ratings & Configurations... 5 10. Winding Connection... 5 11. Construction... 6 11.1 Transformer Enclosure & Cooling... 6 11.2 Primary Terminals... 6 11.3 Secondary Terminals... 7 11.4 Earthing Terminal... 7 11.5 Painting... 7 11.6 Lifting Facility... 7 11.7 Size... 7 11.8 Rating Plate... 7 12. Testing... 8 11.1 Type Test... 8 11.2 Routine Tests... 8 11.3 Test Certificates... 8 13. Documentation and Support... 8 13.1 Documentation Requirements... 8 13.2 Design Drawings... 8 13.3 Drawing Format... 9 13.4 Technical Maintenance Plan... 9 13.5 Maintenance Manual... 9 13.6 Installation Instruction Manual... 9 14. Appendix A Transformer Details... 10 14.1 Terminals and Tappings... 10 15. Appendix B Design Management Requirements... 11 16. Appendix C Technical Data Schedule Form... 12 PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 2 of 13
1. Purpose This document is the technical specification for a 230V/110V or 400V/110V Transformer for use in MTM s Signalling Network. 2. Scope This document applies to the supply of a single phase Transformer with a primary voltage of 230V phase to neutral (it shall be considered as non-effectively earthed) and secondary voltage of 110V. Alternatively the single phase Transformer can have a primary voltage of 400V phase to phase and secondary voltage of 110V (Table 1). This Transformer may be used to supply signalling equipment off a 230V or 400V Bus. 3. Abbreviations ACCB Alternating Current Circuit Breaker Electrol Electrical Systems Control Centre MTM Metro Trains Melbourne 4. Definitions For all technical terms refer to AS 60076. 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. References & Legislation 5.1 Standards The Transformer shall comply with all relevant Standards, including: AS 2374 AS 60076 Power Transformers 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. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 3 of 13
6. Background The Transformer will be used for the purpose of converting power from a 400V or 230V supply to a 110V supply for signalling equipment and other purposes. Due to the variable nature of these uses, the following will be specified in a separate Scope of Works document: Primary Voltage (or equivalent table of ratings to that shown in Section 9) Rated Power 7 General Requirements 7.1 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. 7.2 The Transformer shall be a dry type with enclosed terminals, for an indoor installation or within a field enclosure. 8. Operating Conditions 8.1 Service Conditions 8.1.1 The operating 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. 8.1.2 Transformers designated for indoor installation shall be mounted on a concrete floor inside a substation building or suitable annex. 8.2 Electrical Conditions 8.2.1 Supply to the primary winding of the Transformer will be taken from an ACCB. The primary supply will be either 400V phase to phase or 230V phase to neutral, 50 Hz. It shall be considered as non-effectively earthed. 8.2.2 The secondary winding will be connected to a switchboard via a suitable circuit breaker. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 4 of 13
9. Ratings & Configurations This specification covers two primary voltages. The specific ratings and characteristics of each of these are listed in Table 1. Table 1 Transformer ratings and Characteristics. Type 400/110V 230/110V Rated Primary Voltage 400V 230V Rated Secondary Voltage 110V Single phase to Phases neutral Single (shall be phase to considered phase noneffectively earthed) 3kVA 6kVA Typical Rated Power 10kVA 15kVA 20kVA Rated Frequency 50Hz Primary winding highest voltage for equipment <3.6kV Secondary winding highest voltage for equipment <1.1kV Rated primary short-duration power frequency withstand voltage 10kV RMS Rated primary lightning impulse withstand voltage 20kV peak Rated secondary short-duration power frequency withstand voltage 10kV RMS Rated secondary lightning impulse withstand voltage 20kV peak Maximum Sound Power Level 56dBA Short-circuit apparent power of the supply system 1.25MVA Winding Vector Ii0 Regulation @ 0.6 pf 4% Percentage Impedance 4% 10. Winding Connection 10.1 All insulation used in the transformers shall be non-hygroscopic and designed to withstand continuously a temperature of one hundred degrees centigrade. 10.2 After winding, the completed coils shall be thoroughly impregnated with an insulating compound under the vacuum process in accordance with Australian Standard Power Transformers AS 2374. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 5 of 13
10.3 The composition of the insulating compound shall be such that it will not soften or ooze out under the continued exposure to the maximum working temperatures. 10.4 None of the materials used shall disintegrate under the continued action of heat and shall not carbonise, become brittle or lose their flexibility, with the maximum working temperatures. 10.5 Tappings 10.5.1 The primary side shall have only primary voltage of 230V or 400V (depending on what primary is specified). 10.5.2 The tappings on the secondary terminals shall allow for 110V, 120V and 125V (refer to appendices) 11. Construction 11.1 Transformer Enclosure & Cooling 11.1.1 The Transformer shall be enclosed by a ventilated metallic enclosure cooled by naturally circulated external air. The enclosure shall be suitable for indoor installation or field enclosure. 11.1.2 The transformer shall be naturally cooled - it shall be Class AN. 11.1.3 The enclosure shall provide a minimum ingress protection of IP 21 for indoor installations, in accordance with AS 60529. 11.1.4 The case of the transformer shall be of un-corrugated welded sheet steel not less than 3mm thick. 11.1.5 The transformer case shall have a top cover so arranged that it can easily be removed when the transformer is in position connected ready for working, but will prevent the ingress of foreign substances. The cover shall also cover the primary terminals. 11.2 Primary Terminals 11.2.1 The primary terminals shall be located within the transformer enclosure. 11.2.2 The terminals shall be at least 400mm from the cable entry point to allow for the unscreened length of a typical cable termination. 11.2.3 The terminal studs shall be of suitable size to accommodate crimp lugs for the largest cable size (25mm 2 copper cable, minimum stud size should be M8) 11.2.4 Appropriate cable supports shall be provided within the enclosure such that the weight of the input cable is not taken by the electrical connections 11.2.5 Terminals shall be suitably located to accept cables entering the enclosure from below the transformer, through an appropriate non-ferrous gland. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 6 of 13
11.3 Secondary Terminals 11.3.1 The secondary terminals shall be located on the opposite side of the transformer enclosure to the primary terminals, externally to the enclosure. 11.3.2 The terminals shall be suitable for directly connecting to appropriately terminated low voltage cables, suitably sized for the rating of the transformer. 11.3.3 The terminal studs shall be of suitable size to accommodate crimp lugs for the largest cable size (50mm 2 copper cable, minimum stud size should be M8) 11.3.4 Appropriate cable supports shall be provided within the enclosure such that the weight of the output cable is not taken by the electrical connections 11.3.5 The terminals shall be suitably located to accept cables entering the enclosure from below the transformer, through an appropriate non-ferrous gland. 11.4 Earthing Terminal 11.4.1 The transformer frame shall be directly connected to the room or enclosure earth. Two pre-drilled M12 holes shall be provided on opposite sides of the transformer for this purpose. 11.5 Painting 11.5.1 All metal surfaces shall be prepared in accordance with Australian Standard Metal Finishing Preparation and Pre-Treatment of Surfaces AS 1627 prior to the application of protective primer to Australian Standard Paints for Steel Structures Epoxy Primer (two packs) AS 3750.13. 11.5.2 The final colour coat shall be Y11 Canary Yellow in accordance with Australian Standard Colour Standards for General Purposes AS 2700S and the transformer shall be supplied with touch-up paint. 11.6 Lifting Facility 11.7 Size 11.6.1 The Transformer shall be fitted with a facility for lifting and moving by a forklift. 11.6.2 The base shall be fitted with two channel section with minimum dimensions of 100 mm x 50 mm suitable for lifting the Transformer with a forklift. 11.7.1 The transformer and enclosure shall be as compact as possible, and shall occupy a total floor area no greater than approximately 450mm by 450mm. 11.7.2 The maximum height of the transformer enclosure shall be 450mm from the top of the base channel sections. 11.8 Rating Plate 11.8.1 The Transformer Rating Plate shall comply with the requirements of AS 60076. 11.8.2 The tap link connections and positions shall be clearly shown on the rating plate 11.8.3 The rating plate shall be constructed of stainless steel and shall be securely riveted to the body of the transformer. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 7 of 13
11.8.4 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 12.1.1 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 12.2.1 All routine tests as described in Clause 10 of AS 60076.1:2005 shall be performed on the Transformer at the manufacturer s factory. 12.2.2 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 12.3.1 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. 12.3.2 The test certificates shall be forwarded to MTM and the results approved by MTM prior to delivery. 13. Documentation and Support 13.1 Documentation Requirements 13.1.1 All documentation shall be provided in English. 13.1.2 One electronic and eight paper copies of the each document shall be provided and the content shall be identical in each copy. 13.1.3 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 multipage documents shall be uniquely numbered. It shall be possible to readily determine if all pages of a document are present. 13.1.4 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: i. Construction details of the Transformer including dimensions. ii. iii. Physical layout and arrangement of the components of the Transformer. Mounting requirements for the Transformer. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 8 of 13
iv. Physical layout and arrangement of the primary and secondary terminals. v. Drawings of the Transformer Rating Plate and data vi. 13.3 Drawing Format All other drawings required for Installation, Testing, Commissioning, Operation and Maintenance 13.3.1 All drawings shall comply with PTV Infrastructure Drafting Standard and shall be submitted for MTM approval prior to manufacturing. 13.3.2 Files shall be provided in Microstation format on compact disk (CD). 13.4 Technical Maintenance Plan 13.4.1 A Technical Maintenance Plan which establishes the maintenance policy for the Small Power 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. 13.4.2 The Technical Maintenance Plan shall contain a list of any recommended spare parts, detailing price, supplier and procurement lead-times. 13.4.3 The Technical Maintenance Plan shall detail safe disposal procedures applicable for when the Small Power Transformer is no longer serviceable (recycling, hazardous waste etc.). 13.5 Maintenance Manual The Maintenance Manual shall detail: a) All of the servicing activities. b) Any overhaul instructions. c) The adjustment procedures. d) The changing of components for repairs, and e) Fault-finding procedures. f) 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 13.6.1 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 9 of 13
14. Appendix A Transformer Details 14.1 Terminals and Tappings The following Terminal voltage and marking shall be provided: Figure 1 Terminal Voltage Marking The following name plate and details shall be provided to comply with AS60076.1: a) Kind of transformer (for example transformer, auto-transformer, series transformer, etc.) b) Number of this standard. c) Manufacturer's name, country and town where the transformer was assembled. d) Manufacturer's serial number. e) Year of manufacture. f) Number of phases. g) Rated power (in kva or MVA). (For multi-winding transformers, the rated power of each winding shall be given. The loading combinations shall also be indicated unless the rated power of one of the windings is the sum of the rated powers of the other windings.) h) Rated frequency (in Hz). i) Rated voltages (in V or kv) and tapping range. j) Rated currents (in A or ka). k) Connection and phase displacement symbol. l) Short-circuit impedance, measured value in percentage. For multi-winding transformers, several impedances for different two-winding combinations are to be given with the respective reference power values. m) Type of cooling. (If the transformer has several assigned cooling methods, the respective power values may be expressed as percentages of rated power, for example ONAN/ONAF 70/100 %.) n) Total mass. o) Mass and type of insulating liquid with reference to the relevant IEC standard. p) Maximum system short-circuit power or current used to determine the transformer withstand capability if not infinite. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 10 of 13
15. Appendix B 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 Small Power Transformer which clearly shows: The overall dimensions of the Transformer and details of the enclosure Details of the proposed primary cable 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 11 of 13
16. Appendix C 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) 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 @0.6pf Losses Iron Loss (at Rated Primary Voltage) (W) Copper Loss (at Rated Primary Current) (W) 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 12 of 13
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 13 of 13