IAN BANHAM AND ASSOCIATES PART B - SECTION 2

TRANSFORMERS

SECTION 2

TRANSFORMERS

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SECTION 2

TRANSFORMERS

INDEX
1.0  GENERAL .........................................................................................................................3 
2.0  PRODUCTS .....................................................................................................................5 
3.0  EXECUTION ...................................................................................................................13 

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1.0 GENERAL

1.1 Description of works

The scope of work shall include the design, manufacture, testing at workshop,
insurance, transport, delivery to site and installation, testing, commissioning, handing
over and maintenance during guarantee period for 11KV/400V, dry type transformers
complete with all accessories as specified herein and as shown on the related
drawings, in accordance with Local Authority (Kahraama) requirements and to their
approval.

No. of transformers and rating shall be as indicated in the related drawings.

1.2 Quality Control/Assurance

The transformers offered shall be of a make having ISO 9000 Series Certification
issued by an Internationally Recognized Agency of West Europe, USA or Japan, and
should have been tested in a “Recognized Independent Testing Laboratory” as per
IEC, including “Short Circuit Withstand Test”, and they should have good supply record
of similar transformers. Supply record of last Five (5) years shall be submitted with the
Offer. Offers not complying with this will not be considered.

The Contractor shall note that compliance of the transformer manufacturer with the
provisions of this Specification does not relieve him of the responsibility of supplying
transformers and accessories of proper design electrically and mechanically suited to
meet the operating guarantees at the specified service condition.

The transformers shall in general comply with IEC Publication 76 and the particular
requirements of this Specification and to Local Authority approval.

The Quality Control/Quality Control/Assurance duties shall be performed by the

Contractor and be audited and verified by a reputable Independent Third Party. The
system of quality control verification by the Third Party shall be in accordance with ISO
9000 Standards of Quality Control/Assurance.

The Manufacturer shall offer standard equipment to perform the duty stated in this
specification. Any variations of the Manufacturer's standard package from this
specification must be stated by the Manufacturer, otherwise it will be assumed that all
equipment offered is in accordance with this specification.

Equipment manufacturing record books, equipment record books (Data Books) and
operating and maintenance manuals shall also be submitted.

1.3 Codes and Standards

The following Codes and Standards shall, to the extent specified herein, form a part of
this specification. Where a specific edition date is not indicated, it shall be taken that
the most current edition (including addenda) in effect at the time of vendor’s proposal
submittal shall apply.

Latest regulations and requirements of Local Authority (Kahraama)

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International Electrotechnical Commission (IEC)

IEC76 Power Transformers

IEC85 Thermal Evaluations and Classification of Electrical Insulations

IEC 185 Current Transformers

IEC 233 Tests on Hollow Insulators for Use in Electrical Equipment

IEC 529 Classification of Degrees of Protection Provided by Enclosures

IEC 551 Measurement of Transformer and Reactor Sound Levels

IEC 606 Application guide for power transformers

International Organization for Standardization (ISO)

ISO 8503-2 Preparation of steel substrates before application of paints and related
products – Surface roughness characteristics of blast cleaned steel substrates

Part 2: Method for the grading of surface profile of abrasive blast cleaned steel –
Comparator procedure

Document Precedence

It shall be the vendor’s/manufacturer’s responsibility to be, or to become,

knowledgeable of the requirements of the referenced Codes and Standards.

The vendor shall bring to Contractor’s attention, any apparent conflict between this
specification, the related data sheets, the Codes and Standards and other
specifications mentioned herein. Resolution and/or interpretation precedence shall be
obtained from the Contractor in writing before proceeding with the design/manufacture.

In case of conflict, the order of precedence shall be:

Latest regulations and requirements of Local Authority..
This Specification
Industry Codes and Standards (IEC)

1.4 Submittals

1.4.1 The Contractor shall submit all Technical descriptions, data sheets, catalogues and
other supporting material with the offer to enable the Engineer fully evaluate the
proposal as to its compliance with the Specification. As a minimum the Contractor
shall submit the following:

All Technical Schedules, duly filled-in and signed.

All the drawings and information called for by this Inquiry including:

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General arrangement of Transformer showing all important dimensions, together with

mountings/accessories.

General Arrangement showing masses, main dimensions, arrangement of auxiliary

components and the minimum clearances required for ventilation and safety during
operation and maintenance.

Foundation plan, including foundation loading.

Schematic and connection diagrams covering all equipment pertaining to the
transformer.

Type and special test certificates, for a similar transformer having identical design and
rating.

Instrument Schedule.

Details of HV Cable Terminations/bushings.

Details of MV Cable Terminations/bushings.

Temperature Monitoring System.

Details of Housing.

Schedule of recommended spare parts for a period to Engineer’s approval.

Technical Manual giving installation, operation and maintenance instructions.

Detailed Summary of Deviations from the Specification.

Brochures and Catalogues for standard transformers.

Applicable Design Specifications.

Lists of Accessories included in the Bid.

Approval of Local Authority to the proposed transformer along with ‘MAR’

2.0 PRODUCTS

2.1 Transformers

2.1.1 Transformers shall be built under strict Quality Control/Assurance procedures to

comply with IEC 76 and or IEC 726 and shall have a guaranteed life time of 30 years.

2.1.2 Transformers shall be suitable for continuous operation at full load for at least 30,000
hours without maintenance requiring the transformer to be de-energized.

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2.1.3 Temperature rise of windings at any tap setting, measured by resistance and
temperature rise on top of oil measured by thermometer shall not exceed 50°C and
45°C respectively, at rated kVA and at ambient temperature not exceeding the job site
design temperature.

2.1.4 The MV neutral conductor and terminal of polyphase general service transformers shall
be located next to the phase terminals and be dimensioned to carry not less than that
of the load of the phase conductors and terminals.

2.1.5 The rated withstand voltages shall comply with IEC 76-3, Table II. "List 2" - rated
lightning impulse withstand voltage levels - shall apply.

2.1.6 Transformers shall fully comply with Local Authority requirements/regulations.

2.2 Manufacturing Requirements

2.2.1 Dry-Type Distribution and Power Transformers

a Description: NEMA ST 20, IEEE C57.12.01, ANSI C57.12.50, UL 1562 listed

and labeled, dry-type, 2-winding transformers.

1. Indoor, ventilated vacuum-pressure impregnated and with insulation

system rated at 220 deg C with an 80 deg C average winding
temperature rise above a maximum ambient temperature of 40 deg C.

b. Primary Connection: Air terminal compartment with removable door. Tin-

plated copper bar for incoming line termination, predrilled to accept terminals
for indicated conductors.

c. Primary Connection: Transition terminal compartment with connection

pattern to match switchgear.

d. Secondary Connection: Air terminal compartment with door. Tin-plated

copper bar for incoming line termination, predrilled to accept terminals for
indicated conductors.

e. Secondary Connection: Transition terminal compartment with connection

pattern to match switchgear.

f. Insulation Materials: IEEE C57.12.01, rated at 220 deg C.

g. Insulation Temperature Rise: 80 deg C, maximum rise above 40 deg C.

h. Basic Impulse Level 95 kV.

i. Full-Capacity Voltage Taps: Four nominal 2.5 percent taps, 2 above and 2
below rated primary voltage.

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j. Full-Capacity Voltage Taps: Four nominal 2.5 percent taps below rated
primary voltage.

k. Cooling System: AA/FFA, self-cooled, and with provisions for future forced-
air-cooled rating, complying with IEEE C57.12.01.

1. Automatic forced-air cooling system controls, including thermal

sensors, fans, control wiring, temperature controller with test switch,
power panel with current-limiting fuses, indicating lights, alarm, and
alarm silencing relay.

l. Sound level may not exceed, sound levels listed in NEMA TR 1 and IEC 551.

m. Impedance: percent shall not exceed Kahraama regulations.

n. High-Temperature Alarm: Sensor at transformer with local audible and visual

alarm and contacts for remote alarm.
2.2.2 Cable Connecting Boxes

2.2.2.1 General

Cable connecting boxes shall be made of steel and shall be dimensioned to allow
termination of the specified cables.

The enclosures shall offer a minimum degree of protection IP55, in accordance with
IEC 529.

Separate cable connecting boxes shall be provided for the connection of the specified
cables to:

a) The high-voltage side of the transformer.

b) The medium-voltage side of the transformer.

c) The transformer auxiliary circuits (direct measuring alarm/trip devices, CT

secondaries, etc.).

d) The off-load tap changer.

Auxiliary cable boxes shall be mounted on the side of the transformer in an accessible
position.

Auxiliary and medium voltage cable connecting boxes shall be air-insulated. They shall
be designed to prevent deterioration or failure due to the accumulation of
condensation and exposure to ultraviolet sun rays.

The covers of all cable boxes shall be secured, using nonloosening bolts or screws.
The cover of all cable boxes shall not be removable without the use of tools.

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2.2.2.2 Main Cable Connecting Boxes

The design of the main cable connecting boxes shall meet the following requirements:

Air-Insulated Boxes

The dimensions of H.V. boxes shall not be less than those stated hereunder:

- Minimum clearance between live metal of different phases : 127mm.

- Minimum clearance between live metal and earth : 76mm.
- Minimum creepage distance over insulator : 127mm.

Connection boxes for multicore cables shall be of a type which minimizes the cable
bending requirements (e.g. split type box).

They shall allow single-core conductors to be connected straight on to the terminating

point without the need to bend the conductors. Gland plates shall be constructed from
a nonmagnetic material.

H.V. and L.V. cable boxes shall be positioned on the side walls of the transformer. Top
mounted cable boxes are not acceptable.

All connections shall be sized to carry the maximum continuous current, and also the
provided through-fault currents. Test certificates or calculations shall be available for
all main cable connecting boxes to confirm short circuit withstand capability.

Removable cover access plates shall be provided with handles or, when having a mass
of 25 kg or more, shall be provided with lifting lugs.

All cable connections shall be by a combination of Elastimold type bushings and elbow
connectors. Both bushings and elbow connectors shall be supplied by transformer
manufacturer.

Where Elastimold type bushings and elbow connectors cannot be used due to
limitations on current rating, Raychem type or similar heat shrinkable terminations shall
be used.

For neutral point earthing of star connected transformers, a separate neutral cable box
shall be provided with adequate space to accommodate free issue neutral C.T.’s. On
four wire systems the neutral shall be brought out to the main cable box as well as to
neutral cable box.

2.2.3 Cable Terminations

2.2.3.1 Main Cable Terminations

Cable types and sizes shall be as indicated on the drawings. Single core phase and
neutral cable terminations shall be provided with brass or bronze compression-type
cable glands, mounted on a nonmagnetic gland plate.

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For earthing the neutral point of star-connected transformers, an additional

compression-type cable gland shall be installed for an insulated single-core cable.

2.2.3.2 Auxiliary Cable Termination

Undrilled gland plates shall be provided at the bottom of the cable box(es) for all
external cables.

These gland plates shall be separate from those used for the cabling interconnecting
the on-skid auxiliary equipment.

2.2.4 Cable Screen and Armor Earthing

Facilities shall be provided for the earthing of each cable protective screen and/or
armor inside each cable connecting box, including those for secondary or auxiliary
circuits.

Earthing bolts, nuts and washers shall be provided in each box.

For earthing the screen and/or armor of single-core cables a copper earthing bar shall
be provided complete with an earthing bolt, nuts and washers for each cable.

2.2.5 Terminals

2.2.5.1 Main Terminals

Terminals (and lugs where appropriate) shall be suitable for the cable conductors.

For MV single core cable terminations clamping methods shall be used in order to
avoid cable alignment problems associated with lugs.

All terminals shall be clearly and indelibly marked to identify the phase connections in
accordance with the connection diagram on the rating plate.

2.2.5.2 Auxiliary Terminals

Individual terminals shall be provided for each external cable core.

Terminals shall be of the nonloosening wedge type, obviating the need for cable lugs,
and constructed in such a way that direct contact between screw, bolt or nut and
conductor is avoided.
The terminals shall be logically arranged, circuit by circuit, with adequate barrier shields
and spacers in between them.

Terminals shall be clearly and indelibly marked in accordance with the transformer
auxiliary wiring diagrams.

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2.2.6 Cable Supports and Clamps

Suitable cable supports and clamps for the main cables shall be provided to within 500
mm of the bottom of the cable boxes. The mounting of the cables shall not obstruct the
transformer cooling system.

The spacing between supports/clamps for the main cables shall not exceed 500 mm.

2.2.7 Bushing Insulators

All bushings shall meet the requirements specified in IEC 137 and IEC 233. Minimum
creepage distance for high voltage bushing installed inside a box and not exposed to
the environment shall be as indicated earlier.

The internal winding ends that is tied to the bushings shall always remain under the
oil/liquid level.

2.2.8 Auxiliary Wiring

Auxiliary wiring shall be PVC insulated 600/1000V grade, stranded copper conductors,
minimum size 2.5 mm2.

All auxiliary wiring and cabling shall be ferruled in accordance with the Manufacturer’s
wiring diagram.

All external auxiliary cabling on the Transformer shall either be wire braided or wire
armored.

2.2.9 Frame Earthing

Transformers shall be provided with two earth terminals on the outside of the
transformer mainframe or tank wall, for connection to an external earthing grid. Each
earth connection shall consist of a brass or stainless steel M 10 bolt with nuts and
washers. They shall be located on opposite sides of the transformer, preferably near
the main cable boxes.

All metallic components, such as cable boxes and their internal earthing bars or studs,
shall be bonded to the transformer mainframe or tank.
2.2.10 Current Transformers

When current transformers are included with the transformer, they shall be in
accordance with IEC 185, and comply with requirements as specified in the
Requisition.

All secondary terminals of current transformers shall be wired in armored cables to a

terminal block in the transformer auxiliary cable connecting box.

The terminal shall be provided with short-circuiting links. One side of the secondary
winding of each current transformer circuit shall be earthed at the terminal block.

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The current transformer for the neutral–earth connection of low voltage transformer
winding shall be of the bar primary type and be located in the Neutral terminal box.

2.2.11 Off Circuit Tap Changer

A manually operated off circuit tap changer shall be provided on the HV winding with
freely accessible operating handle for varying the turn’s ratio without producing phase
displacement. It shall meet the following requirements:

The tapping range shall be ± 2.5% in 5 steps.

The tapping switch shall be positively located in each tap position and shall be lockable
only in those positions. The operating handle shall be provided with padlock facilities to
lock the tap changer in each position.

Mechanical end stops shall be provided.

The operating handle shall be of metal and sized to allow operation without the need
for tools. It shall be located in a directly accessible position (i.e. not requiring the
removal of any covers).

Tap positions shall be clearly marked in line with the data given on the rating plate.

One handle shall operate all phases simultaneously.

2.2.12 Mounting and Handling Facilities

The transformers shall be mounted on wheels.

The transformer skids shall have rounded off beam ends and shall be provided with
pulling lugs/holes to enable site movements.

Transformers, and associated cooling equipment, when transported separately, shall

each be provided with adequate lifting lugs to facilitate transport to, and assembly at
site. Additional lugs on the tank covers shall be provided for lifting the cover, if the
cover is removable.

Transformers with an assembled mass of more than 2000 kg shall be provided with
jacking pads.

2.2.13 Rating and Diagram Plate

Rating and diagram plates shall be of stainless steel. They shall be permanently fixed
to a readily accessible and nonremovable part of the transformer. CT (if provided)
ratios shall be stated on the rating and diagram plate. Purchase order No. and
Transformer Tag No. shall also be stated on this plate. Rating plate shall bear, as a
minimum, the information required by IEC 76-1 for oil type transformers.

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2.2.14 Noise

2.2.14.1 Measuring Method

Measurement of noise levels of transformers and associated equipment shall comply

with IEC 551.

2.2.14.2 Noise Limits

The maximum sound pressure level (SPL) developed by the transformer with ONAN
cooling at a distance of 0.3 m shall not exceed the value given by the following
equation:

SPL = 46 + 5 log 10 P dB(A)

where P is stated in kVA.

Compliance with the noise limits shall be achieved by methods other than the provision
of sound attenuation enclosures.

2.2.15 Surface Preparation, Galvanizing and Finishing

Transformers shall have a surface finish which complies with the manufacturer’s
standard for enhanced protection against corrosion in outdoor climates. The paint
system applied shall provide adequate protection against the adverse effects of the
corrosive climate with salt and H2s contents.

The finish of internal walls of tank, covers, connecting boxes and cooling systems shall
effectively protect against the effects of corrosion and the influence of the oil or
synthetic liquid used in the transformer.

External surface preparations, prior to the overall paint finish, shall comprise at least
the following:

Radiators and corrugated tanks shall be hot-dip galvanized

Tanks and other parts shall be hot-dip galvanized, or zinc sprayed if too large for the
hot-dip process. The surface preparation of tank walls shall include blast cleaning to
surface preparation SP 5 in accordance with SSPC or SA 2.5 - 3 per ISO 8503-2.

Welded areas, such as the tank cover rims of hermetically sealed transformers, shall
be painted with zinc-rich paint.

The Contractor shall provide, with the submittal details of all surface treatments,
galvanizing, base, intermediate and final painting systems, including the minimum
thickness of each application, and an assurance of suitability to meet the specified
requirements.

The external paint finish color shall be manufacturer standard colour and subject to
meet the above requirements. Inside the main tank the color shall be white to facilitate
internal inspection.

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2.2.16 Special Tools

Special tools required for erection, commissioning and maintenance shall form part of
the order and be shipped together with the transformer.

3.0 EXECUTION

3.1 Installation

Installation of the transformers shall be strictly in accordance with manufacturer’s

recommendations, as per approved shop drawings, relevant IEC, standards,
requirements and to Local Authority approval.

Contractor shall closely coordinate with Local Authority:

i) To obtain approval of the transformer and related accessories prior to ordering

the equipment.

ii) For all technical requirements of installation

iii) Approval on the installation of transformer including cabling and terminations.

3.2 Tests

Before leaving the MANUFACTURER'S works, each transformer shall be inspected

and tested.

All transformers shall be subjected to the "routine tests" as modified by this

specification.

The test results shall be recorded in a test report.

Type and special tests certification shall be made available for equipment of identical
design and rating. Inability to meet this requirement shall be made known to the
Engineer.

The type, special and routine tests are summarized hereafter.

3.2.1 Routine Tests

Measurement of winding resistance (IEC 76-1)

Measurement of voltage ratio and check of voltage vector relationship (IEC 76-1)
Measurement of impedance voltage (principal tapping), short-circuit impedance and
load loss (IEC 76-1)

Measurement of no-load loss and current (IEC 76-1)

Dielectric tests: Induced over voltage withstand test and separate-source voltage
withstand test (IEC 76-3)

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Tests on-load tap changers, where appropriate (oil-immersed transformers only)

(IEC 76-1)

3.2.2 Type Tests

Temperature-rise tests (IEC 76-2)

Dielectric tests: Full-wave impulse-voltage withstand test (IEC 76-3)

3.2.3 Special tests

Dielectric tests: Impulse-voltage withstand tests including chopped waves (IEC 76-3)

Measurement of zero-sequence impedance on three-phase transformers (IEC 76-1)

Short-circuit test (IEC 76-5)

Measurement of acoustic sound level (IEC 551)

Measurement of the harmonics on the no-load current (IEC 76-1)

If special tests other than those listed above are required, the test method shall be
subject to agreement between the manufacturer and the Local Authority.

3.3 Inspection and Tests

Inspection and tests shall be carried out on the completely assembled transformer(s).

Checks shall be made to verify:

a) The correct type and make of the insulation/cooling liquid.

b) The oil-tightness of the tank, interconnecting piping, flanges, valves and fittings.

c) The arrangements for oil sampling, cleaning and filtering.

d) The transportability, skid, lifting, pulling lugs, jacking pads, temporary seals, etc.
The suitability of cable connecting boxes and support clamps for type of cable(s)
specified.

e) The layout of the auxiliary cable boxes and the external cabling system on the
transformer interconnecting operating and measuring devices to the connecting
box.

f) The off-load tap changer equipment.

g) The earth connections.

h) The completeness of the nameplates, rating and diagram plate.

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j) The proper terminal markings. the finish of the transformer and its components.

k) The adequacy of results of the "routine tests".

l) The adequacy of results of the "type tests".

m) The adequacy of results of the "special tests".

n) The contractor shall compile the complete records of the above inspections and
tests in one inspection document and the same shall also be included in the
submittal for ADDC approval.

3.4 Transformer Losses and Tolerances

3.4.1 Losses

The Contractor shall submit with the quotation the calculation of the Net Present Value
(NPV) of the losses of the transformer offered.

The Contractor shall in this case guarantee the values of the no-load and load losses
with tolerances as stated hereafter.

The Contractotor shall carry out the calculations, using the formula given below, and
using the factors and cost data stated in the requisition:

NPV = (Po + a2.Pk) x 8760 x b x c

where: Po = no-load loss (kW)
Pk = load loss (kW)
a = loading factor (% of transformer rating/100)
b = energy unit cost (cost/kWh)
c = capitalization factor from Annuity Table 1 attached to the specification.

The Contractor shall provide details of the no-load and load losses, together with
alternative values for alternative designs, where appropriate. Any forced cooling
system electrical load consumption shall be declared separately.

3.4.2 Tolerances

The tolerances of the losses on which the calculation of the NPV as stated in (12.1) is
based, shall be reduced from those normally allowed by IEC 76-1, Table III, as follows:

Total Loss : + 5% instead of 10%

Component Loss : +10% instead of 15%

These more demanding tolerances shall be guaranteed.

End of Section

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