Engineering Specification Head of Electrical Engineering MESP 050100-01 TECHNICAL SPECIFICATION FOR AN AUXILIARY OR ESSENTIAL SERVICES AND AUXILIARY TRANSFORMER FOR USE IN A RAILWAY SUBSTATION Version: 3 Issued: October 2016 Approved By: Andrew Russack Head of Engineering - Electrical PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION
MESP 050100-01 Approval Amendment Record Approval Date Version Description 20/03/2015 1 Initial issue under MTM. Replaces L2-ELN-SPE-009 and issued as Version 1 for new document number. 04/07/2016 2 Updated to include provision for Essential Services and Auxiliary Transformers (typical rated power, winding vectors, terminology throughout). Document name altered. Options for terminals clarified. 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
MESP 050100-01 Table of Contents 1. Purpose... 4 2. Scope... 4 3. Abbreviations... 4 4. Definitions... 4 5. References & Legislation... 4 5.1 Standards... 4 5.2 Latest Issues and Amendments... 5 6. Background... 5 7. General Requirements... 5 8. Operating Conditions... 5 8.1 Service Conditions... 5 8.2 Electrical Conditions... 5 9. Ratings & Configurations... 6 10. Winding Connection... 7 11. Construction... 7 11.1 Transformer Enclosure & Cooling - Dry Type Transformer... 7 11.2 Transformer Cooling and Other Requirements - Oil Type Transformer... 7 11.3 Primary Terminals... 8 11.4 Secondary Terminals... 8 11.5 Earthing Terminal... 9 11.6 Painting... 9 11.7 Lifting Facility... 9 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... 10 13.1 Documentation Requirements... 10 13.2 Design Drawings... 11 13.3 Drawing Format... 11 13.4 Technical Maintenance Plan... 11 13.5 Maintenance Manual... 11 13.6 Installation Instruction Manual... 12 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 Auxiliary Transformer, or an Essential Services and Auxiliary Transformer, for use in MTM substations. 2. Scope This document applies to the supply of a Power Transformer with a secondary voltage of either 230V phase to phase (unearthed system) or a 400V phase to phase (230V phase to neutral) MEN system and power rating of 50-500kVA for use in a substation installation as part of the MTM Electrical Network. This Transformer may be used to supply substation auxiliary services, the Essential Services Power Distribution Network, maintenance buildings, stations or other similar facilities. 3. Abbreviations ACCB - Alternating Current Circuit Breaker MTM - Metro Trains Melbourne HV - High Voltage 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 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 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. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 4 of 15
MESP 050100-01 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 substation HV supply to a 400V or 230V phase to phase supply for auxiliary power, essential services and other purposes. Due to the variable nature of these uses, the following will be specified at the time of ordering: Primary Voltage (or equivalent table of ratings to that shown in section 9.1) Rated Power Indoor or outdoor installation Type of primary and secondary terminals required Oil insulated or dry type 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 may be either an oil-insulated or dry type. 8. Operating Conditions 8.1 Service Conditions 8.1.1 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. 8.1.2 Transformers designated for indoor installation will be mounted on a concrete floor inside a substation building or suitable annex. 8.1.3 Transformers designated for outdoor installation will be mounted on a concrete slab, unprotected from the weather. 8.2 Electrical Conditions 8.2.1 Supply to the primary winding of Auxiliary Transformer will be taken via an ACCB or Fuse Isolator from an HV distribution supply. The HV supply will be either 22kV or 11kV, 3 phase, 50 Hz. It shall be considered as non-effectively earthed. 8.2.2 The secondary winding will be connected to a 400V or 230V (phase to phase) switchboard via a suitable circuit breaker. 8.2.3 The transformer may be subject to significantly unbalanced loads on the secondary side on a regular basis for the purpose of supplying, via a step up transformer, a single phase Essential Services or Signal Power Distribution System. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 5 of 15
9. Ratings & Configurations 9.1 This specification covers two primary voltages. The specific ratings and characteristics of each of these are listed in the table below Type 22kV Essential Services and Auxiliary Transformer 22kV/230V ph-ph Auxiliary Transformer 11kV Essential Services and Auxiliary Transformer 11kV/230V ph-ph Auxiliary Transformer Phases 3 3 3 3 Rated Primary Voltage 22kV 22kV 11kV 11kV Rated Secondary Voltage phase to phase 400V 230V 400V 230V Standard Values of Rated Power 100kVA 160kVA 250kVA 50kVA 100kVA 100kVA 160kVA 250kVA 50kVA 100kVA Rated Frequency 50Hz 50Hz 50Hz 50Hz Primary winding highest voltage for equipment 24kV 24kV 12kV 12kV Secondary winding highest voltage for equipment <1.1kV <1.1kV <1.1kV <1.1kV Rated Primary shortduration power frequency 50kV RMS 50kV RMS 28kV RMS 28kV RMS withstand voltage Rated Primary lightning impulse withstand voltage 125kV peak 125kV peak 75kV peak 75kV peak Rated Secondary shortduration power frequency 10kV RMS 10kV RMS 10kV RMS 10kV RMS withstand voltage Rated Secondary lightning impulse withstand voltage 20kV peak 20kV peak 20kV peak 20kV peak Maximum Sound Power Level Reduced Level Reduced Level Reduced Level Reduced Level Short-circuit apparent power of the supply system 500MVA 500MVA 350MVA 350MVA Winding Vector Dyn1 Dyn11 Dzn0 or Yyn0(d) Dyn11 Regulation @ 0.6 pf 5% 5% 5% 5% Percentage Impedance 4% 4% 4% 4% 9.2 The winding vector may be altered if the reason for it is established and submitted to MTM for approval. For Essential Services and Auxiliary transformers, the phase angle must not be changed. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 6 of 15
10. Winding Connection 10.1 Five output taps on the primary windings shall be provided for the following range: +5.0%; +2.5%; 0%; -2.5%; -5.0%. 10.2 The selection of the tapping shall be off-load. 10.3 The tap changing device shall have a continuous rating of 100% of the Transformer full load current. 10.4 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, and shall be readable from a distance of 1.2 m. 10.5 For dry type transformers, the tap position may be selected either as described in clause 10.4, 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 11.1.1 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. 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, or IP 43 for outdoor installations, in accordance with AS 60529 11.2 Transformer Cooling and Other Requirements - Oil Type Transformer 11.2.1 The oil preservation system can be freely breathing or sealed type. The transformer shall be naturally cooled (ONAN). 11.2.2 The insulating oil shall comply with AS 60076 and shall not contain any Polychlorinated Biphenyl (PCB). 11.2.3 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. 11.2.4 A concentration of PCB greater than one part per million will result in rejection of the transformer. 11.2.5 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 PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 7 of 15
11.2.6 Where a fully sealed transformer is offered the oil gauge and thermometer pocket need not be included. 11.3 Primary Terminals 11.3.1 The primary terminals shall be one of three configurations as outlined in the table below: Configuration Primary Enclosed (fixed/bolted lid cable box) Primary Enclosed (hinged door cable box) Requirements An accessible air insulated cable box shall be provided, suitable for the connection of an insulated cable rising from below through an appropriate non-ferrous gland. The terminals shall be at least 400mm from the cable entry point to allow for the length of a typical cable termination and shall be suitable for connecting to appropriately lugged 50-185 mm2 XLPE insulated screened cable. Appropriate cable supports shall be provided within the enclosure such that the weight of the input cable is not taken by the electrical connections. An accessible air insulated cable box shall be provided, suitable for the connection of an insulated cable fitted with dead break elbow connectors complying with IEEE Std 386, rising from below through an appropriate non-ferrous gland. The terminals shall be at least 400mm from the cable entry point to allow for the length of a typical cable termination and shall be suitable for connecting to 50-185 mm2 XLPE insulated screened cable. The bushing wells shall be suitable for connection of dead break elbows which comply with IEEE Std 386. Appropriate cable supports shall be provided within the enclosure such that the weight of the input cable is not taken by the electrical connections. Primary Exposed Open bushing terminals shall be provided, suitable for the satisfactory connection of bare copper aerial conductors of 70-100 mm 2 cross section from above or horizontal to the Transformer. 11.4 Secondary Terminals 11.4.1 The secondary terminals shall be located on the opposite side of the transformer enclosure to the primary terminals. 11.4.2 The terminals shall be suitable for directly connecting to appropriately terminated LV cables, suitably sized for the rating of the transformer. 11.4.3 The secondary terminals shall be one of three configurations as outlined in the table below: PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 8 of 15
MESP 050100-01 Configuration Secondary Enclosed Secondary Exposed 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 50mm2 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. Exposed bushings shall be provided, suitable for connection of an insulated cable rising from below or dropping from above the bushings. The cable may be up to 50mm2 of the copper insulated type and will be terminated with appropriate lugs for connection to the bushings. 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 11.5.1 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. 11.5.2 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 11.6 Painting 11.6.1 Dry type transformer - The enclosure shall be properly prepared and painted so as to be suitable for outdoor installation irrespective of designated installation location. 11.6.2 Oil Insulated Transformer - The transformers external tank shall be properly prepared and hot dip galvanised. 11.6.3 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 11.7.1 The Transformer shall be fitted with a facility for lifting and moving by both a crane and a forklift. 11.7.2 Suitable lifting lugs shall be provided for lifting by a crane which shall be capable of lifting the whole weight of the Transformer. 11.7.3 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. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 9 of 15
11.8 Size 11.8.1 The transformer and enclosure shall be as compact as possible, and shall occupy a total floor area no greater than approximately 1300 mm x 1300 mm. 11.8.2 The maximum height of the transformer enclosure shall be 1200mm from the top of the base channel sections. 11.9 Rating Plate 11.9.1 The Transformer Rating Plate shall comply with the requirements of AS 60076. 11.9.2 The tap link connections and positions or tap changer positions shall be clearly shown on the rating plate 11.9.3 The rating plate shall be constructed of stainless steel and shall be securely riveted to the body of the transformer. 11.9.4 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. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 10 of 15
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 multi-page 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 13.2.1 The following drawings must be supplied: i. Construction details of the Transformer including dimensions. ii. iii. iv. 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. 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 must comply with the 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 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 Transformer is no longer serviceable (recycling, hazardous waste etc.). 13.5 Maintenance Manual 13.5.1 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 PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 11 of 15
13.5.2 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 12 of 15
MESP 050100-01 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
MESP 050100-01 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) 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 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 Secondary Terminals Manufacturer Type (mm) (mm) depth height Voltage Rating (V) Current Rating (A) Height above base of enclosure (mm) Cable box dimensions (if applicable) (mm) width (mm) (mm) depth height PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 15 of 15