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OIL-INSULATED SUBSTATION TRANSFORMERS (00-E-SP-290117-00) Novartis Vaccines & Diagnostics Pernambuco Biotech Plant Jaboato dos Guararapes, PE

Revision History Rev. 0 1 Date 14-Jun-2013 26-Jun-2013 By Jos Orts Vlad Colodeiciuc Pages 5 13 Remarks Issued for tender.

OIL-INSULATED SUBSTATION TRANSFORMERDRY TYPE TRANSFORMERS 00-E-SP-290117-00 2614-Jun-2013

Table of Contents
PART 1 GENERAL................................................................................................................... 3 PART 2 PRODUCTs................................................................................................................ 6 PART 3 EXECUTION............................................................................................................. 14

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PART 1 GENERAL 1.1 GENERAL REQUIREMENTSS A. The transformer shall be built under strict quality assurance procedures to comply with IEC 60076 and shall have a guaranteed life time of 20 years. The transformer shall be suitable for continuous operation at full load for at least 5 years without maintenance requiring the transformer to be de-energized. Manufacturers: Eaton/ABB/ Siemens/Schneider/ALSTOM The equipment has to be formerly approved by local Power Distribution Company CELPE.

B. C. 1.2 1.3

ALL REQUIREMENTS OF DIVISIONS 0 AND 1 FORM A PART OF THIS SECTION. SCSCOPE OF WORK A. Work Included Work Included The scope of work shall include the design, manufacture, testing at workshop, insurance, transport, delivery to site at Jaboato dos Guararapes, PE and installation, testing, commissioning and handing over for an oilinsulated 5MVA(ONAN)/6.5MVA(ONAF) transformer, 69 kV/13,8 kV complete with all accessories as specified herein and as shown on the related drawings for the substation. Prior to arrival of equipment at job site, installing contractor shall review certified shop drawings, instruction manuals and installation procedures. Coordinate rigging requirements with rigging Contractor. Before equipment is removed from truck, installing contractor shall inspect for shipment damages per manufacturers written instructions.

Oil-insulated type transformers, through 69 kV -13,8 kV. Related Work Not Specified in This Section: B. Electrical Testing. 1. 1.4 Power Conductors and Cables.

HANGERS AND SUPPORTSCODES AND STANDARDS Furnish new equipment meeting applicable CELPE, ABNT and IEC Standards: NBR 5356 NBR 7036/7037 NBR 5034 NBR 5416 Power transformer - Specifiition Acceptance, erection and maintenance of liquid insulated transformers Bushings For Alternating Voltages Above 1,0 Kv Load application on power transformer

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IEC 60044-1

Instrument Transformers Part 1: Current transformers IEC 60076 Power transformers IEC 60085 Designation Electrical Insulation- Thermal Evaluation &

IEC 60099-1 Surge Arresters Non-Linear Resistor Type Gapped Arresters for A.C. Systems IEC 60137 Insulated Bushings for alternating voltages above 1000 V IEC 60214 Tap-Changers IEC 60296 Fluids for Electro technical applicationsUnused mineral insulating oils for transformers and switchgears IEC 60076-10-1 Power Transformers Part 10-1: Determination of Sound Levels Application Guide Document Precedence It shall be the Contractor/Manufacturer responsibility to be, or to become, knowledgeable of the requirements of the referenced Codes and Standards. The Contractor shall bring to attention, any apparent conflict between this specification, the Codes and Standards and other specifications mentioned herein. Resolution and/or interpretation precedence shall be obtained in writing before proceeding with the design/manufacture. In case of conflict, the order of precedence shall be: 1. CELPE requirements 2. This Specification 3. 1.5 Industry Codes and Standards .

SUBMITTALS A. B. Catalog cuts and data. Receiving, installation, testing, operation, and maintenance instructions - five weeks before the equipment is shipped. Receiving instructions shall be affixed to the shipping enclosure or wrapping. C. D. Recommended spare parts list. Confirm shipping splits and weights with the installing contractor to ensure proper rigging services and access to equipment location by others. E. Submit sound levels per ABNT and IEC standards to ensure the transformer meets these requirements. F. Routine and Type Test Reports

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G.

Test reports for climatic tests and environment as per IEC 60076 -11 shall be submitted.

H. A. B. C. D.

Written approval of the equipment by CELPE. TOC (Total Cost of Ownership) calculations Refer to submittal procedures from procurement or construction management. Submit catalog cuts with product data, percentage regulation at 100% and 80% regulation, no load and full load losses in watts and sound level in decibels. REFERENCES Transformers shall be designed, manufactured, tested and installed in accordance with ABNT/IEC, local codes, requirements of authorities having jurisdiction and in particular, the following: ABNT NBR 7036, 7037, 5034, 5356 and 5416. Any other local applicable norms, standards and regulations.

E. F.

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PART 2 PRODUCTS

1.6 A.

OIL-FIELD TRANSFORMERS Main Characteristics 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Number of phases : 3 Frequency : 60 HZ Primary Voltage : 69,000 V Secondary Voltage : 13,800 V Primary Connection : Delta Secondary Connection : Wye Tap Changer : Manual Connection Vector: Dyn11 Primary BIL : 350 KV (corregido) Secundary BIL : 110 KV

Transformer and radiators shall be constructed of steel and delivered to site complete. The transformer shall be suitable for lifting or being rolled into position and being skid mounted. The transformer shall be conservator type and fitted with Buchholz relay. This shall have both alarm and trip contacts and installed complete with an air relief valve, flanges and valves to enable removal without the need to drain the oil. A pressure relief device shall be fitted on the tank cover. The capacity of the oil conservator tank shall be such that it will amply cover the expansion of the oil volume of the transformer under the extremes of ambient temperatures and for all operating conditions specified. It shall be equipped with a magnetic oil level gauge complete with alarm contacts with an ample scale to cover the total oil contraction and expansion. At its lowest part the oil conservator shall have provision to collect and remove water and sludge. A breather shall be provided with silica gel dehydrating capsule and an air lock. Conservator shall be membrane type split conservator tank, utilizing a method of avoiding air/oil contact and moisture contamination of the oil. The radiators shall be provided with isolating valves fitted at the oil inlets and outlets and with an oil filling plug and oil drain valve. This valve shall be provided with cap and padlock facilities or alternatively designed to require the use of special tools to operate.
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The transformer shall be fitted with one filling/filter connection valve near the top of the tank and oil drain/filter valve near the bottom of the tank. The filling and draining valves shall be fitted with sealing caps and padlock facilities, or alternatively designed to require the use of special tools to operate. A cable connection shall be installed between the Buchholz relay and a terminal box, located on the lower part of the tank wall, for the alarm/trip functions. All wiring and cabling between equipment mounted on the transformer shall be provided by the contractor. Individual cable cores shall have numbered ferrules to indicate the corresponding terminal connection. All wiring shall be fixed to prevent damage caused by vibration and other hazards. The normal rating 5 MVA shall be the continuous rating outdoor, under the maximum specified temperature and humidity in Jaboato dos Guararapes, PE, Max. 50C, 100% saturation (Non-coincidental). The transformer shall be naturally air cooled (ONAN), but designed and equipped so that fans can be fitted at a later date to allow a minimum increase in rating to 6.5 MVA (ONAF). The VENDOR shall submit calculations to substantiate temperature for both the ONAN and ONAF ratings. All components shall be rated to meet this requirement. A minimum of two fans shall be provided, control shall be from contacts on a winding temperature indicator or a dial type thermometer set at the maximum naturally cooled oil temperature. A local test control station shall be included to provide: 1. 2. A local start signal simulating the thermometer contacts closing. A local stop signal simulating the thermometer contacts opening a fan failure alarm contact. The contractor shall provide the associated control cubicle mounted on the transformer. The auxiliary power supply shall be 380 V, 3 phase, 4 wire, 60 Hz. The transformers shall be cooled by means of bolted, flange-mounted radiators. Welded or other non-detachable cooling tubes shall not be used. The transformer shall be filled with the Shell Diala-B oil or approved equivalent. If the environmental and/or CELPE requirements prohibit the use of mineral oil, a synthetic substitute may be used. Datasheets shall be available confirming the characteristics of the oil proposed. The liquid shall not contain, nor be contaminated with, polychlorinated biphenyls (PCBs). VOLTAGE RATIO The normal voltage ratio of the transformer on normal tapping and on no load shall be 69000/14500V.

1.7

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1.8

INSULATION CLASS & TEMPERATURE RISE The rated withstand voltages shall comply with IEC 60076-3, Table 2, Series-Irated withstand voltages for transformer windings with highest voltage for equipment Um170kV The insulation levels shall comply with Table 3 of IEC 60076-11 List 2- Rated lightning impulse withstand voltage Insulating materials in the range Class B to H inclusive may be used in accordance with the temperature rises stated in IEC 60076-2, Table III, considering ambient temperature of 40 C Temperature rise of windings at any tap setting, measured by resistance and temperature rise on top of oil measured by thermometer shall not exceed 50C and 45C respectively, at rated kVA and at ambient temperature not exceeding the site design temperature of 54C.

1.9

CORE ASSEMBLY For three-phase transformers, in-line, three-limb cores shall be used. All parts of the core shall be of robust design capable of withstanding any shocks to which they may be subjected during lifting, transportation HV & LV WINDINGS Windings shall be uniformly insulated. Transformer windings shall be of copper. Full power tappings shall be provided in the high voltage windings. Winding connections inside transformers shall be brazed or crimped.

1.10

1.11

CONNECTIONS The transformer shall be wound to British Standard Specification 171 Vector Reference Dyn 11 with fully rated neutral.

1.12

OFF CIRCUIT TAPPINGS A manually operated off-circuit tap changer shall be provided. It shall meet the following requirements: a. b. The tapping range shall be + 5% in 2.5% 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. All tap positions shall be rated at full kVA. 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

c. d. e.

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covers). f. Tap positions shall be clearly marked in line with the data given on the rating plate. g. One handle shall operate all phases simultaneously. 1.13 ENCLOSURE The transformer shall have a surface finish for enhanced protection against corrosion in outdoor climates. The paint system applied shall provide adequate protection against the adverse effects of the climatic conditions specified. 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: a. b. 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 BS EN ISO 8503-2. Welded areas, such as the tank cover rims of hermetically sealed transformers, shall be painted with zinc-rich paint. The external paint finish colour shall be green RAL 7035. Inside the main tank the colour shall be white to facilitate internal inspection. A danger sign with cautionary notice both in PORTUGUESE and ENGLISH shall be affixed on the cover. Temperature Indicator and Alarm shall be provided in easyto-access location. 1.14 INTERNAL EARTHING All metal parts of the core, frame and tank, etc., shall be maintained at earth potential. 1.15 EXTERNAL 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.

c. d.

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1.16

HV TERMINATIONS Cable connecting boxes shall be made of steel and shall be dimensioned to allow termination of the cables specified within the data sheets. The enclosures shall offer a minimum degree of protection IP55, in accordance with IEC 60529. Separate cable connecting boxes shall be provided for the connection of the specified cables to: a. b. c. The high-voltage side of the transformer. The low-voltage side of the transformer. The transformer auxiliary circuits (direct measuring alarm/trip devices, CT

d. The forced cooling installation NOTE: items (c) and (d) may be combined Auxiliary cable boxes shall be mounted on the side of the transformer in an accessible position. The covers of all cable boxes shall be secured, using non-loosening bolts or screws. The cover of all cable boxes shall not be removable without the use of tools. Water shedding metal sun/rain canopies with an overhang of at least 50 mm on all sides shall be fitted over all cable connecting boxes. An air space of at least 50 mm above the top cover shall be provided for ventilation. Side mounted single phase oil filled terminal boxes shall be provided on the high voltage side of the transformer for terminating high voltage XLPE insulated single core cables. Each H.V. terminal box shall have an oil-to-oil high voltage bushing and a connector for terminating the H.V. bushing to the cable terminal unit. The H.V. terminal boxes shall be piped together and brought up to the transformer conservator. The pipe to the conservator shall have a Buchholz relay for monitoring faults in the terminal boxes. Each H.V. terminal box shall have a provision to fill and drain the oil. The H.V. terminal boxes shall have an oil level gauge, or a sight glass and a mechanical pressure relief device.

1.17

LV TERMINATIONS Auxiliary and low 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 rays. For LV single core cable terminations clamping methods shall be used in order to avoid cable alignment problems associated with lugs.

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All terminals shall be clearly and indelibly marked to identify the phase connections in accordance with the connection diagram on the rating plate. Individual terminals shall be provided for each external cable core. Terminals shall be of the non-loosening 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. For neutral point earthing of the transformer, a separate neutral cable box shall be provided with adequate space to accommodate free issue neutral C.T.s. 1.18 NOISE LEVEL Measurement of noise levels of transformers and associated equipment shall comply with IEC 60076-10. The maximum sound pressure level (SPL) developed by the transformer with ONAN cooling at a distance of 0.3 m shall not exceed 65dB. 1.19 NAME PLATE Rating and diagram plates shall be of stainless steel. They shall be permanently fixed to a readily accessible and non-removable part of the transformer. Contractors reference number and Transformer Tag No. shall also be stated on this plate. Rating plate shall bear, as a minimum, the information required by IEC 60076-1 In addition Standard Danger Sign with Warning in both Portuguese and English shall be fixed in a prominent location. A. B. C. D. Provide 60 hertz, liquid insulated, two winding, with three phase and neutral grounding resistor . Windings may be aluminum or copper. Cores shall be constructed of non-aging electrical grade steel with high magnetic permeability and low loss characteristics. High-voltage full-capacity taps and sound power levels shall conform to the latest revisions of ABNT/IEC Standards. Transformers will be provided with the following elements at least: 1. 2. 3. 4. 5. Oil gauge. Sudden pressure relay. Pressure relief device. Valve for oil filling. Plug for removal of oil sample.

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E.

Transformers lifetime depends greatly upon the windings and core temperature in service. ABNT (NBR 5356) allow a temperature of 55C for oil and 65C for windings. Oil temperature shall be shown in a display. Lugs shall be applied by the Installing Contractor. Enclosures shall be provided with lifting eyes or brackets and ventilated openings designed to prevent access to live parts. Front and rear covers shall be removable to provide wiring access. The core and coil assembly must be grounded to the enclosure by means of a factory installed flexible copper grounding strap. Transformer technical data will be described in the identification stainless steel plate placed on it. The accessories will be in accordance with ABNT. The core shall be constructed of steel sheet silicon grain oriented, cold-rolled, lowloss and high permeability. The bushings must have physical and electrical characteristics as prescriptions NBR 5034. The bushings of TP's for external use must have minimum leakage distance of 25 mm / kV. There should be an expansion chamber at the top to compensate for variations in the oil volume due to temperature changes

F. G.

H. I. J. K.

L.

1.20 LIQUID INSULATED TRANSFORMERS INDOOR A. Transformers smaller than 35 kV in primary winding could be installed indoor in accordance with one of the following: 1. 2. 3. B. Areas where no combustible materials are stored and a liquid confinement area is provided. Areas with an automatic fire extinguishing system and a liquid confinement area. Oil-insulated transformers installed in a vault constructed with the exceptions specified in 450.26 NFPA 70 (National Electric Code).

Transformers over 35 kV in primary winding with nonflammable fluid-insulate shall be installed in a vault. It shall be furnished with a liquid confinement area and a pressure relief vent.

1.21 LIQUID INSULATED TRANSFORMERS OUTDOOR A. All transformers not included in previous specifications shall be installed outdoor. This installation must comply with IEC 61936-1 Power installations exceeding 1 kV a.c.

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1.22 MANUFACTURERS A. Manufacturers: ABB, COMTRAFO, BLU TRAFOS, ADELCO, ZILMER, WEG or similar.

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PART 3 EXECUTION 1.23 LIQUID INSULATED SUBSTATION TRANSFORMERSINSTALATION Installation of the transformer shall be strictly in accordance with manufacturers recommendations, as per approved shop drawings, CELPE requirements and to company approval.

1.24 TESTS A. GENERAL

Inspection and tests shall be carried out on the completely assembled transformer. Checks shall be made to verify: a. b. c. d. The correct type and make of the insulation/cooling liquid. The oil-tightness of the tank, conservator, cooling system, interconnecting piping, flanges, valves and fittings. The arrangements for oil sampling, cleaning and filtering. The transportability, skid, lifting, pulling lugs, jacking pads, temporary seals, etc. The suitability of cable connecting boxes and support clamps for type of cables specified. The sun/rain canopies of cable connecting boxes. The layout of the auxiliary cable boxes and the external cabling system on the transformer interconnecting operating and measuring devices to the connecting box. The off-load tap changer. The on-load tap changer equipment and its remote control panel, if specified. The earth connections. The completeness of the nameplates, rating and diagram plate. The proper terminal markings. the finish of the transformer and its components. The adequacy of results of the "routine tests". The adequacy of results of the "type tests". The adequacy of results of the "special tests".

e. f.

g. h. i. j. k. l. m. n. B.

ROUTINE TESTS

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a. b. c. d. e. f. g. C. h. i. D.

Measurement of winding resistance (IEC 60076-1) Measurement of voltage ratio and check of voltage vector relationship (IEC 60076-1) Measurement of impedance voltage (principal tapping), shortcircuit impedance and load loss (IEC 60076-1) Measurement of no-load loss and current (IEC 60076-1) Dielectric tests: Induced over voltage withstand test and separate-source voltage withstand test (IEC 60076-3) Tests on-load tap changers, where appropriate (oil-immersed transformers only) (IEC 60076-1) Partial discharge test (dry-type transformers only) (IEC 60076-11) Temperature-rise tests (IEC 60076-2) Dielectric tests: Full-wave impulse-voltage withstand test (IEC 600763)

TYPE TESTS

SPECIAL TESTS j. Dielectric tests: Impulse-vo ltage withstand tests including chopped waves (IEC 60076-3) k. l. m. Measurement of zero-sequence impedance on three-phase transformers (IEC 60076-1) Measurement of acoustic sound level (IEC 60076-10-1) Measurement of the harmonics on the no-load current (IEC 60076-1)

1.25 ACCESSORIES AND PROTECTIVE DEVICES a. Two tank earthing bosses, size M10 shall be provided to facilitate earth connections. Earthing bosses shall be located on diagonally opposite corners of the tank base. b. Dial type thermometer for indicating top liquid temperature with two hands, one showing oil temperature at time of reading and second showing maximum temperature reached since last resetting. Thermometer shall have hermetically sealed normally closed alarm contacts set to open at maximum self-cooled operating temperature. c. Liquid level gauges for transformer tank, conservator tank and disconnecting chamber. The transformer shall be fitted with magnetic oil level gauges with alarm contacts. d. Silica-gel dehydrating breather for conservator type transformer. e. Lifting eyes to facilitate cover removal and lifting hooks to facilitate lifting entire transformer. f. Rating plate, terminal marking plate and tag number plate shall be of stainless
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steel. g. Filter valves. h. Oil sampling device at the bottom of the tank. i. j. Pressure relief devices, with contacts. Off-circuit tapping switch (lockable).

k. Buchholz relay. l. Jacking pads and pulling eyes. m. Skid and Rollers. n. Oil sampling valve for on-line oil sampling unit that measures combustible gases in the oil. NOTE: The Thermometer, oil level gauge, and silica-gel breather shall be so positioned that they are visible from outside the transformer compound. Before installation, must be checked that all items are in good conditions. The oil should be checked by inspecting the liquid level gauge. Transformer should be handled in the normal upright position, but in no case tilted more than 15 from vertical, unless instructions have been given to the contrary Ground the neutral to structural steel. Use flexible raceway to prevent noise transmission through raceway. Install transformers to comply with manufacturer's instructions, applicable requirements of codes and authorities, and in accordance with recognized industry practices. Field Quality Control, per Specification Section 260503: Prior to energization, check unit connections for tightness. Re-torque as necessary. Prior to energization, check units for continuity, short circuits and grounds. Testing for transformers shall include insulation resistance test and taps verification. Insulation resistance tests shall be performed winding to winding and winding to ground Upon completion of installation of transformers, energize primary circuitry at rated voltage and frequency from normal power source, and test transformers, including, but not limited to, audible sound levels, to demonstrate capability and compliance with requirements. When possible, correct malfunctioning units at site, then retest to demonstrate compliance; otherwise, remove and replace with new units, and proceed with retesting. Set transformer taps to provide optimum voltage conditions at utilization equipment. Locate transformers so that adjacent equipment, and heating effects of adjacent equipment, do not adversely affect transformer cooling. Locate transformers so that heat from transformers do not affect adjacent equipment, and to provide adequate spacing for transformer cooling air circulation. The transformer must be energized initially no-loaded. If the transformer is provided with onload switch should be activated in all the derivations Terminate primary and secondary conductors per Section 260519.
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*** END OF SECTION ***

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