Engineering Standard Electrical

EP 02 44 00 01 SP 11 KV VOLTAGE REGULATOR

Version 2.0

Issued May 2010

Owner: Approved by:

Chief Engineer Electrical Wilfred Leung Chief Engineer Electrical Authorised by: Wilfred Leung Chief Engineer Electrical

Disclaimer This document was prepared for use on the RailCorp Network only. RailCorp makes no warranties, express or implied, that compliance with the contents of this document shall be sufficient to ensure safe systems or work or operation. It is the document users sole responsibility to ensure that the copy of the document it is viewing is the current version of the document as in use by RailCorp. RailCorp accepts no liability whatsoever in relation to the use of this document by any party, and RailCorp excludes any liability which arises in any manner by the use of this document. Copyright The information in this document is protected by Copyright and no part of this document may be reproduced, altered, stored or transmitted by any person without the prior consent of RailCorp.

Engineering Standard

RailCorp Engineering Standard Electrical 11 kV Voltage Regulator

EP 02 44 00 01 SP

Document control
Version 2.0 Date June 2008 May 2010 Summary of change Last Technical Review Application of TMA 400 format

Contents
Introduction.............................................................................................................................................3 1 2 Scope and Application ...........................................................................................................3 References...............................................................................................................................3 2.1 Australian and International Standards .....................................................................3 2.2 RailCorp Standards ...................................................................................................4 2.3 Railcorp Reference Documents.................................................................................4 Technical Specifications ........................................................................................................4 Regulator fittings and accessories .......................................................................................5 4.1 Rating plate................................................................................................................5 4.2 Regulator terminals....................................................................................................5 4.3 Core and coils............................................................................................................5 4.4 Regulator oil...............................................................................................................5 4.5 Oil level indicator .......................................................................................................5 4.6 Oil drain valve ............................................................................................................6 4.7 Oil filler cap ................................................................................................................6 4.8 Regulator lifting and lashing down facilities...............................................................6 4.9 By pass arrester.........................................................................................................6 4.10 Surge arrester............................................................................................................6 4.11 Pressure relief device ................................................................................................6 4.12 Tank earthing terminal ...............................................................................................6 4.13 Surface finish .............................................................................................................6 4.14 Regulator tap changer control and settings...............................................................6 4.15 Remote control communication .................................................................................7 Integrated System Support Requirements ...........................................................................7 5.1 Integrated Support Objectives ...................................................................................7 5.2 Equipment Supplier Deliverable ................................................................................8 Testing......................................................................................................................................8 6.1 Type tests ..................................................................................................................8 6.2 Routine tests..............................................................................................................8 Data set associated with the equipment...............................................................................9 7.1 Information.................................................................................................................9 7.2 Technical Schedule at Appendix A............................................................................9 7.3 Life Cycle Costing......................................................................................................9 Technical Schedule ...............................................................................................10

3 4

Appendix A

Appendix B Request for Tender Check list..............................................................................12 Application...............................................................................................................................12 Information to be supplied at time of Tender ..........................................................................12 Information to be sought from Tenderer .................................................................................12
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RailCorp Engineering Standard Electrical 11 kV Voltage Regulator

EP 02 44 00 01 SP

Introduction
This specification is about single phase voltage regulators for use on RailCorps 11kV network. Voltage regulators will be used to provide automatic voltage regulation on 11 kV sides of power transformers up to 1000 kVA where no automatic tap changer is provided. Occasionally voltage regulators will also be used on other parts of RailCorps 11kV network such as distribution lines carrying load up to 1000 kVA

Scope and Application

The purpose of this document is to provide minimum electrical, mechanical, safety and operational requirements of step voltage regulators for use in RailCorps 11kV, 3-phase 50 Hz distribution network. This specification covers the design, engineering, manufacture and testing of single phase or three-phase step voltage regulators. The step voltage regulators specified are intended to provide automatic voltage regulation on 11 kV sides of power transformers up to 1000 kVA where no automatic tap changer is provided.

3
3.1

References
Australian and International Standards
The following Australian and International Standards are either referenced in this document or can provide further information. ANSI C57.15 Requirements, terminology, and test code for step voltage and induction voltage regulators AS/ ISO 1000 The international system of units (SI) AS 1265 Bushings for alternating voltages above 1000 volts AS 1767 Insulating liquids, specifications for unused mineral insulating oils for transformers and switchgear AS 1824 Insulation coordination definitions, principles and rules AS 1931 High voltage testing techniques AS 1939 Degrees of protection provided by enclosures for electrical equipment Electrical Power Equipment Integrated Support Requirement AS 2067 Switchgear assemblies and ancillary equipment for alternating equipment for alternating voltages above 1 kV AS 2344 Limits of electromagnetic interference from overhead power lines and high voltage equipment installation AS 2374 Power Transformers AS 2650 Common specification for high voltage switchgear and control gear AS 2700 AS 2700-1996 Colour standards for general purposes AS 3000 AS 3000-2000 Electrical Installations AS 4025 Paints for equipment including ships AS 60038 AS 60038-2000 Standard voltages

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RailCorp Engineering Standard Electrical 11 kV Voltage Regulator

EP 02 44 00 01 SP

3.2

RailCorp Standards
Several significant sets of requirements applicable to voltage regulators are common to other classes of equipment and are set out in the following RailCorp standards. The equipment shall comply with the relevant requirements set out therein. EP 00 00 00 13 SP Electrical Power Equipment Design Ranges of Ambient Conditions. EP 12 00 00 01 SP High Voltage & 1500 System Earthing References & Definitions EP 12 00 00 02 SP Low Voltage Distribution and installations Earthing References and Definitions EP 12 10 00 10 SP System Substation Earthing EP 00 00 00 12 SP Electrical Power Equipment Integrated Support Requirement EP 00 00 00 15 SP Common requirement for Electrical Power Equipment EP 12 10 00 10 SP System Substation Earthing

3.3

Railcorp Reference Documents

The following RailCorp documents are either referenced in this document or can provide further information EP 00 00 00 01 TI RailCorp Electrical system general description

Technical Specifications
Description Common requirements Applicable standards System parameters Rated voltage System frequency Number of phases Max 3 phase symmetrical fault current Basic insulation level Lightning Impulse withstand voltage One minute power frequency withstand Regulator ratings Cooling class Breathing method Line load (kVA) Line load current (A) No. of phases on the regulator 11kV 50 Hz 3 20 x nominal current ANSI C57.15. or equivalent Requirement

95 kV peak 28 kV rms

Liquid immersed self cooled (ONAN) sealed 1000 (approx) 50 A bank of three single phase units, or a single three phase unit

Tapping range
o

+10% to -10% with 16 equal steps 55

Temp rise over 50 C

o

ambient ( C)

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Description Means of tap changing Radio interference voltage levels Radiator mounting Tapchanger Type Rating Power supply Voltage regulation control

Requirement On load automatic Comply with AS1137-3 Attached to tank On-load 1.5 times max rating Self powered Automatic electronic

Regulator fittings and accessories

As a minimum, the regulators shall include the following fittings/accessories. In addition all fittings/accessories that are necessary for safe operation of the equipment shall be deemed to be included, whether mentioned in this specification or not.

5.1

Rating plate
Two rating plates shall be provided on each regulator, one (1) affixed to the main tank and the other in front of the control cubicle, in accordance with the stated standards. The rating plate and all other labels shall be in English.

5.2

Regulator terminals
All bushings shall be outdoor type oil-air bushings. The colour of the porcelain glaze shall be light grey, similar to T33 Mist Blue, as set out in AS 2700. Bushing minimum nominal creepage distance shall be as provided in the schedules. The bushings shall have a continuous current rating not less than 150% of the full load rating of the regulator at the maximum operating temperature. They shall also be suitable for a through fault current equal to the standard ratings indicated in the schedules. The appropriate designating letter to standards shall be permanently marked adjacent to the respective terminal.

5.3

Core and coils

The core shall be of a low loss design with sturdy clamping that prevents axial movement and allows high short circuit strength

5.4

Regulator oil
Regulators shall be supplied with standard mineral insulating oil that meets the requirements of AS 1767. Regulators shall be thoroughly dried out and be vacuum filled. The moisture content of the oil at the time of filling shall be less than 25 ppm. The regulator oil shall be PCB free to AS 1767 and this shall be stated on the regulator nameplates.

5.5

Oil level indicator

Facilities shall be provided to check for the correct oil level without disassembling the regulator.

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5.6

Oil drain valve

The regulator shall be fitted with a drain valve and oil sampling device.

5.7

Oil filler cap

Oil filler cap shall screw onto a male threaded pipe on the lid and should be located so that a 20mm OD pipe may be passed through it to the bottom of the tank.

5.8

Regulator lifting and lashing down facilities

Lifting lugs/eyes are required for the tank, core/windings and lid. The tank lifting lugs or eyes are to be suitable for lifting the complete regulator. Lugs shall also be provided on the regulator for bolting down when ground/platform mounted. Lugs shall also be provided on the regulator for lashing to a vehicle during transport.

5.9

By pass arrester
Single-phase style regulators that require a bypass arrester across the series winding shall be fitted with a metal oxide type arrester (MOV), to protect the winding from surges.

5.10

Surge arrester
Mounting brackets shall be provided for the addition of surge arresters adjacent to the source (S), load (L), and source-load (SL) bushings. The brackets shall be fully welded: spot welding is not acceptable.

5.11

Pressure relief device

A pressure relief device shall be fitted to the main tank and tap-changer. The device shall be fitted with a cover designed to direct oil discharges in a downward direction. The device shall be of a self-sealing spring type design.

5.12

Tank earthing terminal

The tank shall have two unpainted stainless steel earthing lugs welded to it at diagonally opposite corners near ground level. The earthing lugs shall have a minimum cross sectional area of 300mm2 and shall be drilled M14 to accept an M12 bolt.

5.13

Surface finish
Regulator tank, radiators and control cubicle shall be of stainless steel construction and painted. The external surfaces shall be painted in accordance with AS 4025. Colour to be storm grey, colour ref. N42 to AS 2700. Alternatively manufacturer may submit its standard painting procedure for RailCorps approval.

5.14

Regulator tap changer control and settings

The regulator shall be fitted with an on-load tap-changer of the high-speed type, having the tapping range and steps as set out in the technical requirements of this specification. The on-load tap-changer and associated equipment shall have a nominal minimum current rating of at least 1.5 times the highest tapping current for the continuous maximum rating of the regulator.

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The following facilities shall be provided; Tap changer shall be self-powered i.e. any auxiliary power needs to drive tap changer mechanism shall be obtain from 11 kV terminals with in the tank. It shall be designed to work without an external auxiliary supply. A 3-position selector switch Auto Off Manual Clearly visible tap position indicator with distinctive marking when on neutral tap A six-digit operations counter, which counts every tap change. Manual raise and lower control switch at the regulator. Each switching operation shall initiate only one tap-change. The switch shall to return to off-position and the tap-change completed before initiating next tap-changing operation. Manual handle for emergency and maintenance operation. Insertion of the handle shall lock out by automatic mechanical means all electrical operation. A means to indicate whether the voltage is inside or outside the set voltage band. All wiring in the control box shall be either colour coded or labelled for easy identification. Alternatives will be subject to RailCorp approval. All printed circuit boards shall be coated for fungi and moisture protection. A thermostatically controlled heater assembly with an ON/OFF switch if required. The set voltage, defined as the voltage level to which the control will regulate, on a defined base, shall be adjustable from (-) 10% to (+) 10% of the base voltage in increments no larger than 0.5% or better. Set voltage bandwidth shall be adjustable from 1% to 6% in increments no larger than 0.5%. Time delay shall be adjustable from 10 to 240 seconds, in increments of 10 seconds. All control and auxiliary equipment associated with the tap-changer shall be mounted in a separate weatherproof lockable cabinet. Cable from control box to regulator

5.15

Remote control communication

The regulator control shall be capable of interfacing with RailCorps SCADA equipment. The remote communication for the unit shall support DNP 3.0 up to and including level 3. The unit shall provide a RS 232 communication port that supports asynchronous V.24 functionality. It shall be possible to connect the RS 232 to modem interface in order to allow local protocol and communication trouble shooting. Outputs shall be optically isolated. It shall be possible to provide at least the following information for communication to SCADA via the RS 232 port. Current (A). Voltage (V). Active power (W). Power direction (import or export). Local/supervisory switch position. Tap position raise/lower control. Tap position indication. Tap in neutral position.

6
6.1

Integrated System Support Requirements

Integrated Support Objectives
The voltage regulator manufacturer must establish and provide the information required to operate and maintain the equipment throughout its operational life, in a cost effective

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manner and to a level that is consistent with the planned operational performance and usage of the voltage regulator. This includes Specifying Maintenance requirements Installation instructions Spares support Operation and Maintenance Manuals Training and Support equipment and tooling

6.2

Equipment Supplier Deliverable

The integrated support requirements are a significant deliverable in the procurement of the voltage regulator. Manuals, training, documentation and other support deliverables shall be in accordance with EP 00 00 00 12 SP, Electrical Power Equipment Integrated Support Requirements.

Testing
The following sections set out in detail the testing requirements for regulators. The manufacturer shall provide two (2) copies of certified test reports for all type, routine and special tests. The regulators shall be tested in accordance with stated standards ANSI C57.15.

7.1

Type tests
Voltage regulators shall be of a type tested design. It is expected that at least the following test had been conducted on voltage regulators in accordance with standards ANSI C57.15. Applied frequency Induced potential Impulse test Short circuit test

7.2

Routine tests
Routine tests shall be in accordance with ANSI C57.15 - all tests specified in Section 5.9.1. These tests shall include the following: Resistance measurements of all windings. Ratio test on all tap connections. Polarity test. No load (excitation) loss at rated voltages and rated frequency. Excitation current at rated voltage and rated frequency. Impedance and load loss at rated current and rated frequency. Temperature test (RailCorp may accept results from tests conducted on a unit of the same rating and design). Applied potential test. Induced potential tests. Insulation power factor tests.

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RailCorp Engineering Standard Electrical 11 kV Voltage Regulator

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Data set associated with the equipment

The following data shall be supplied by the manufacturer and maintained for the voltage regulators. The data will remain the property of RailCorp.

8.1

Information
The following information shall be provided by the manufacturer as a minimum. General arrangement drawings for the regulator and control box Control schematic diagrams Software to up-load or down-load data from control box (this will include any accessories required for connection) Operation and maintenance instructions Additional information and requirements as a deliverable under equipment supply is documented in the following specification: EP 00 00 00 12 SP, Electrical Power Equipment Integrated Support Requirements EP 00 00 00 15 SP, Common Requirements for Electric Power Equipment EO 19 00 00 02 SP, Protection System Requirements for High Voltage Network

8.2

Technical Schedule at Appendix A

The information listed in the technical schedule at Appendix A, supplied by the manufacturer, shall be maintained for each voltage regulator.

8.3

Life Cycle Costing

All data and assumptions pertaining to the determination of whole-of-life cost calculations shall be recorded.

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Appendix A

Technical Schedule

The Tenderer shall supply the information listed in this Technical Schedule at tender stage for each Voltage Regulator Voltage Regulator Details Rated Voltage Rated Power Overload Ratings Continuous rating of Tap changer Voltage Regulator Impedance reduced to nominal voltage in kV (Phase to Ground) and rating MVA per single phase unit Transformer Oil details Mass of Regulator (without Oil and including Oil) Volume of Oil in Litres Dimension for construction in mm Bushings Makers type number and material Continuous rating Lighting impulse flashover Creepage distance Air clearance between phases Air clearance between phase & ground Palm dimension mm x mm .V .kVA .%/h .A .% . kg l

A kVp mm mm mm mm ..

IP protection Ambient Conditions Minimum Temperature Maximum Temperature Humidity level Regulation Range of regulation Number of steps for full range Setting Range Bandwidth Range

..0C ..0C ..%

.% . V..V .V..V

Fault Level Requirement Dynamic and Electrical constraints are to be calculated for a minimum fault level of

MVA

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Surge Protection Series Arrester type and ratings Shunt arrester type and ratings Routine and type test certificates . .

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Appendix B

Request for Tender Check list

Application
Request for Tender should be made in accordance with RFT Checklist in Specification EP 00 0000 15 SP, Common requirement for Electrical Power Equipment

Information to be supplied at time of Tender

When this standard is used as the basis for procurement of Voltage Regulator for a particular location, in addition to the general requirement in this standard the following information will need to be supplied related to particular site: Site location Substation Auxiliary supply if any Rated voltage and kVA rating Minimum length of control cable if control is separated from voltage regulator Arresters to be included and fixed on each regulator Access Road limits (Weight, height and time limit) Regulator mounting (Pole mounted or Pad mounted) Colour requirement for outdoor equipment

Information to be sought from Tenderer

Tenders to complete and submit Technical Schedule as per Appendix A Tenders to complete and submit Integrated Support information as per RailCorp Standard EP 00 00 00 12 SP Electrical Power Systems Integrated Support Requirement.

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