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Electromechanical Water-To-Wire Technical Specifications

Section 7 - Main Power Transformer

SECTION 7

MAIN POWER TRANSFORMER

Rev. Date Description Prepared by Reviewed by


0 20-01-2016 Initial Version R.S J.A
Updated with Client
1 22-02-2016 R.S J.A
comments

Rev. 1 7-i Ayanunga Hydroelectric Project


Date: 22/02/2016
Electromechanical Water-To-Wire Technical Specifications
Section 7 - Main Power Transformer

TABLE OF CONTENTS
7 MAIN POWER TRANSFORMER ................................................................................................................ 7-1
SCOPE ................................................................................................................................................. 7-1
GENERAL REQUIREMENTS ............................................................................................................... 7-1
DESIGN CRITERIA............................................................................................................................... 7-1
SUBMITTALS ..................................................................................................................................... 7-11
FACTORY ASSEMBLY AND TESTS ................................................................................................. 7-12
SPARE PARTS ................................................................................................................................... 7-15

Rev. 1 7-i Ayanunga Hydroelectric Project


Date: 22/02/2016
Electromechanical Water-To-Wire Technical Specifications
Section 7 - Main Power Transformer

7 MAIN POWER TRANSFORMER


SCOPE
General
This Section specifies the technical requirements for the main power transformer to be
furnished, complete in accordance with this Technical Specification. All requested data and
requirements shall be treated as minimum required.

Plant to be Furnished
The Contractor shall design, detail, manufacture, factory test, deliver, install, field test, pre-
commission and commission one (1) main power transformer and appurtenances complete in
accordance with this Technical Specification.

The Contractor shall furnish all components and accessories that are usual and required for
the intended use of the transformer, even if they are not specifically called for herein.

The Contractor shall also furnish a complete set of maintenance tools needed for the
adjustment and normal maintenance of the transformer.

GENERAL REQUIREMENTS
The basic materials and methods shall be in accordance Section 2 - General Technical
Specification.

The main power transformer shall be an outdoor, three phase, pad mounted, oil filled, air
cooled unit of proven design.

An impact recorder, Shocklog 248 or equivalent, shall be fitted to the transformer on dispatch
from the manufacturer’s premises. On arrival at Site the recorders logs shall be downloaded
from the unit and a copy handed to the Employer. The impact recorder shall remain in position
on the transformer until the transformer is mounted on its plinth and all installation work is
completed. A second set of log files shall then be downloaded and a copy handed to the
Employer. Any evidence of mishandling of the transformer during transportation and
installation may result in a rejection of the transformer. The Contractor shall ensure that the
impact recorder has sufficient memory and battery life for at least 2 months more than the
scheduled delivery and installation period.

DESIGN CRITERIA
Ratings and Characteristics
The ratings and characteristics of the transformer shall be as follows:

a) Installation Outdoors
b) Frequency 60 Hz
c) Number of windings 2 (primary and secondary)

Rev. 1 7-1 Ayanunga Hydroelectric Project


Date: 22/02/2016
Electromechanical Water-To-Wire Technical Specifications
Section 7 - Main Power Transformer

d) Number of phases 3
e) Type of cooling ONAN
f) Continuous rating of windings on all taps, MVA To match combined generator
output. Not less than 25 MVA
g) Rated Voltage
 High voltage winding (Primary) 138 kV
 Low voltage winding (Secondary) 6.6 kV
h) Highest System Voltage:
 Primary 145 kV
 Secondary 12 kV
i) Basic Impulse Level, Peak:
 High voltage winding (line terminal) 650 kV
 High voltage winding (neutral terminal) 75 kV
 Low voltage winding (line terminal) 75 kV
j) Power Frequency Withstand Voltage during one minute
 Primary terminal 275 kV
 Secondary terminal 28 kV
 Neutral terminal 28 kV
k) Winding Connections: YNd11
 High voltage winding (Primary) Star, solidly grounded
 Low voltage (Secondary) Delta
l) Minimum impedance, on a 24-MVA base, % 12.5%
m) No load taps 5 (±2.5% each)
n) Efficiency, minimum of: 99.5%
Standards
The transformers shall be designed, manufactured, and tested in accordance with the
applicable IEC standards.

Temperature Rise
The observable temperature rise of the transformer or parts thereof as determined by
resistance of the windings, shall not exceed the requirements of IEC60076-2 at rated kVA and
on the tap connections that give the highest winding temperature rise.

Rev. 1 7-2 Ayanunga Hydroelectric Project


Date: 22/02/2016
Electromechanical Water-To-Wire Technical Specifications
Section 7 - Main Power Transformer

Short Circuit Capability


The transformer shall be designed and constructed to successfully withstand, without failure
or injury, the mechanical and thermal stresses caused by current in any winding due to any
type phase or ground fault occurring on the transformer high voltage or low voltage terminal,
for the time period (as a minimum value) specified by IEC60076-5 when the transformer is
applied at a location where infinite short circuit currents are available on both the high voltage
bus and the low voltage bus. No windings shall be below the mechanical and thermal
requirements defined in IEC60076-5.

Bonding
All metal parts of the transformer, except for the windings and other electrical conductors, shall
be equipotential bonded.

Core
The core of the transformer shall be constructed of the highest quality, non-aging, high-
permeability silicon steel especially suitable for the purpose. The steel shall be in thin
laminations, properly annealed after cutting to suitable size and rolled to ensure smooth
surfaces at the edges. Both sides of each sheet shall be insulated with a durable, heat-resistant
enamel or varnish, baked on. The core shall be carefully assembled and rigidly clamped to
ensure adequate mechanical strength to support the windings, to prevent shifting of the
laminations during shipment, and to reduce vibration to a minimum under operating conditions.

The core shall be insulated from the tank and all other metallic parts of the transformer structure
to at least 2.5 kV. A single insulated copper connection shall be used to bond the core to an
insulated bushing on the transformer tank. This connection shall be generously sized for the
prospective short circuit current, and in any case shall not be less than 50mm2. A removable
copper connection between the bushing and the transformer tank shall be provided to facilitate
testing of the transformer internal components without removal of the oil.

Windings
The windings for the transformer shall be made of such material and assembled in such a
manner as are best suited for the particular application. The HV winding shall be non-graded
type with the entire winding insulated to the full line side rating. Proper consideration shall be
given to all factors of service such as high dielectric and mechanical strength of insulation, coil
characteristics, and minimum restrictions to free circulation of oil. Coils shall be made up,
shaped, and braced to provide for expansion and contraction due to temperature changes in
order to avoid abrasion of insulation and to provide rigidity to resist movement and distortion
caused by abnormal operating conditions. Adequate barriers shall be provided between
windings and core and between high-voltage and low-voltage windings. End coils shall have
additional protection against abnormal line disturbances. The entire design, construction, and
treatment of the windings and their assembly on the core shall embody the latest improvements
in the art and conform to best modern practice. The transformer windings shall be designed to
withstand impulse, induced, and dielectric test voltages in accordance with IEC 60076-3.

The transformer shall be capable of withstanding without injury the mechanical and thermal
stresses caused by short circuits on the external terminals of any winding, or windings, with

Rev. 1 7-3 Ayanunga Hydroelectric Project


Date: 22/02/2016
Electromechanical Water-To-Wire Technical Specifications
Section 7 - Main Power Transformer

rated voltages maintained across the terminals of all other windings intended for connection to
sources of energy in accordance with applicable Standards.

Heat stabilized, 100% kraft, paper and board shall be used for conductor insulation, inter-
winding wraps, winding supports etc. The manufacturer shall provide information on the type
of papers and boards used in order to facilitate monitoring of degradation over time by Furan
analysis. The manufacturer shall mount six (6), 20 cm long paper samples from three different
packages used during the insulation of the winding sets to the transformer core during the
winding dry out. Once the winding has been dried out, one sample of each type shall be
handed to the Employer for them to undertake Degree of Polymerization (DP) tests. The
second samples shall be tested by the manufacturer. Should the DP of the test papers be less
than 950, the winding will be rejected.

Tap Changer
The transformer shall be equipped with an externally, manually-operated no load tap changer
rated for the maximum rating of the transformer and suitable for changing connections to the
taps in the windings as tabulated in Section 7.3.1 - Rating and Characteristics. Taps shall be
changed only when the transformer is de-energized. The operating hand wheel shall be
mounted on the side of the case at a convenient height for operating from the floor on which
the apparatus is mounted and shall include an indicating pointer and dial and means for locking
the tap changer in any desired position. The complete tap changing mechanism shall be built
with high electrical, mechanical, and thermal safety factors, and the contacts shall be capable
of withstanding the full short-circuit current of the transformer without injury. Tap changing
contacts and mechanism shall be accessible through manholes in the transformer cover
without requiring untanking or other major disassembly of transformer. The tap changer shall
be removable from the transformer for replacement without untanking the core and coil
assembly.

Terminals (Bushings)
The transformer shall have each high-voltage and each low-voltage lead brought out from the
tank through a bushing. Bushings of like voltage shall be interchangeable between units. All
bushings shall be so designed that there will be no undue stressing of any parts due to
temperature changes, weight of connected conductors, wind loadings, seismic loading,
dynamic forces during short circuit events and adequate means shall be provided to
accommodate conductor expansion. Bushings of the oil-filled type shall be free from oil leakage
and shall be provided with suitable indicators to show oil levels and with convenient means for
sampling oil and draining the bushings from the bottom.

High voltage bushings shall be outdoor type and shall be equipped with a capacitance tap for
use with a bushing potential device. The neutral bushing shall be provided with bolted terminal
connectors for a 120 mm2 copper bar, which shall extend to the bottom of the transformer tank,
and then be connected to the power station grounding system.

Low voltage bushings shall be indoor type installed in a cable box on the side of the
transformer. Cable boxes shall be air insulated and located with the bottom of the box located
at a sufficient level above the bottom of the transformer tank to permit cable termination via a
cable gland.

Rev. 1 7-4 Ayanunga Hydroelectric Project


Date: 22/02/2016
Electromechanical Water-To-Wire Technical Specifications
Section 7 - Main Power Transformer

Each cable box shall be provided with two earth terminals per phase for the following purposes:

 The separate earthing of the copper wire screen and/or armour of each cable.
 The temporary earthing of the cable terminal.
 The temporary earthing of the bushing terminal.
Each cable box shall also:

 Include a removable gland plate made of non-magnetic metal.


 Have an inspection cover with seals and orifices designed in order to prevent
condensation inside the cable box.
 Be rain tight and dust tight to not less than IP55.
 Be positioned so that the cables can be run easily without interference with the
transformer radiators and other fittings.
All porcelain used in the bushing shall be manufactured by the wet process; shall be
homogenous, free from laminations, cavities, and other flaws affecting its mechanical strength
or dielectric quality; and shall be well vitrified, tough, and impervious to moisture. The glazing
of the porcelain parts shall be free from imperfections, such as blisters and burns and shall be
grey in colour.

Surge Arrestors
Surge arrestors shall be fitted to both the high voltage and low voltage terminals of the
transformer. The high voltage surge arrestors shall be mounted on the top of the transformer
tank, adjacent to the high voltage bushings. The low voltage surge arrestors shall be located
in the low voltage terminal box.
Key equipment requirements for the HV surge arrestors are:
 Type Gapless, Metal Oxide
 Standard ANSI/IEEE C62.1 / IEC60099-5
 Maximum system voltage 145 kV
 Rated voltage 120 kV
 MCOV 92 kV
 Rated frequency 60 Hz
 Nominal discharge current 10 kA
 Pressure relief class 3

Key equipment requirements for the LV surge arrestors are:


 Type Gapless, Metal Oxide
 Standard ANSI/IEEE C62.1 / IEC60099-5
 Maximum system voltage 6.6 kV
 Rated voltage 4.8 kV
 Rated frequency 60 Hz
 Nominal discharge current 10 kA
 Pressure relief class 1

Surge arresters shall be of the gapless metal oxide type, other types will not be considered.

Rev. 1 7-5 Ayanunga Hydroelectric Project


Date: 22/02/2016
Electromechanical Water-To-Wire Technical Specifications
Section 7 - Main Power Transformer

The surge arresters shall be suitable for application in a system with solidly grounded neutral.
They shall have a metal top design with corona ring and class 3 porcelain or polymer housing.
The dielectric characteristics shall be coordinated with the electrical protective characteristics
of the arrester. The unit end castings shall be of corrosion resistant aluminium alloy. The
metal oxide compound provided shall ensure a non-linear characteristic for optimum energy
absorbing protective levels. There shall be a pressure relief system to assure maximum safety
and reliability, with vent covers to prevent foreign material from entering vent ports.
Tank
The transformer shall be provided with an oil-tight steel tank. The joints between the case and
cover shall be such that the cover and top section of the case are integral. Gasket or shield
material, which will not deteriorate under service conditions, shall be provided between the top
cover and case. The top cover shall be bolted to the tank.

The transformer tank shall be designed to permit lifting of the complete assembly (including
oil) by crane and jacking. Crane hook locations, and jacking pads shall be provided at
convenient locations on the transformer tank.

The transformer shall be provided with a steel skid base, without wheels. The tank base shall
be designed to equally distribute the load to the foundation and permit moving the transformer
in the direction of either major axis. Anchor bolts shall be provided for fastening the base to
the foundation. In addition, the base shall be designed to allow for anchoring to the foundation
by welding.

Jacking lugs or pads shall be provided for raising the completely-assembled, oil-filled
transformer when the transformer is to be moved. The lugs and tank shall be of ample strength
to avoid overstress or distortion resulting from possible unequal division of weight among jacks.

The supply shall include for one complete set of hydraulic jacks and accessories common to
two transformers. Hand operated oil pumps for the jacks shall be included.

Pulling eyes shall be provided for moving the transformer horizontally.

The transformer tank shall be provided with a hand hole or manhole of size to afford easy
access to the lower ends of bushings, terminals, and the upper portions of the coils. The
transformer shall be provided with eyebolts and/or lugs for lifting the essential parts and for
lifting the completely assembled transformer filled with oil. Guides shall be provided inside the
tank for guiding the cores and windings as they are being removed from or lowered into the
case.

The transformer tank shall be provided with a pressure relief diaphragm or valve of adequate
size to protect the tank against a primary explosion due to arcing below the surface of the oil.
The relief diaphragm shall be designed so as to minimize discharge of oil and to exclude air
and water after it opens. It shall be equipped with a visual alarm indicator and with alarm
contacts.

Two sudden pressure relays, responsive to the rate of rise in pressure, shall be furnished at
diametrically opposite corners of the transformer. The sudden pressure relays shall be
equipped with contacts for unit alarm and tripping.

Rev. 1 7-6 Ayanunga Hydroelectric Project


Date: 22/02/2016
Electromechanical Water-To-Wire Technical Specifications
Section 7 - Main Power Transformer

The transformer tank shall be designed as a pressure vessel and shall be capable of
withstanding without leakage or distortion a full vacuum and an internal gas pressure 25%
greater than the maximum operating pressure resulting from the system of oil preservation
used. The transformer tank shall be designed to be capable of withstanding without rupture an
internal arc energy in excess of 8MJ. In the event of a tank rupture, the first rupture point must
be the tank cover. All valves, fittings, and piping affected by this requirement shall be of correct
design and construction for full vacuum filling.

The transformer shall be provided with approved valves as required for:

a) Draining the tank (flanged-gate valve).


b) Sampling oil from the extreme bottom of the tank.
c) Sampling oil from the top of the tank.
d) Lower filter press connection and complete drain.
e) Upper filter press connection.
f) Isolating each radiator.
g) Air relief or venting from each radiator.
h) Draining oil from each radiator.
i) Draining oil from the tap changer.
j) Filling the tank and radiators.
k) Nitrogen.
l) Conservator.
m) Isolation of Buchholz relay.
n) Vacuum line connection.
o) Gas analysis sampling.

Oil valves shall be specially designed for use with insulating oil and shall hold hot oil without
leaking. An air vent shall be provided on the transformer at the top of the tank and piped to a
valve within reach from the floor for releasing air when the tank is being filled with oil and/or
nitrogen gas.

Two transformer tank grounding pads shall be furnished on opposite sides of the tank near the
transformer base.

Oil Preservation System


7.3.12.1 General

The transformer shall be equipped with a conservator or inert-gas type of oil preservation
system.

Rev. 1 7-7 Ayanunga Hydroelectric Project


Date: 22/02/2016
Electromechanical Water-To-Wire Technical Specifications
Section 7 - Main Power Transformer

7.3.12.2 Conservator or Expansion Tank

Conservator or expansion tank, if furnished for the transformer, shall be equipped with an
expansion diaphragm to prevent air-to-oil contact in the tank. A breather shall be furnished and
connected into the tank on the air side of the diaphragm. Conservator shall be equipped with
a Buchholz relay. The Buchholz relay shall be furnished with contacts for unit alarm and
tripping. In addition, a mechanical pressure relief valve with automatic reseating capability and
a visible flag shall be provided on the transformer cover.

7.3.12.3 Gas Fault Detection System

A gas fault detection system shall be furnished for the transformer with all necessary probes,
capillary tubes, etc. to perform a complete gas analysis. One portable test set shall also be
furnished.

Oil Monitoring

7.3.13.1 General

The transformer shall be provided with an oil level gauge, indicating thermometer, on-line
dissolved gas analyser, temperature detectors and thermal replica relays.

7.3.13.2 Oil Level Gauge

The oil level gauge shall be a magnetic-type with a scale that can be easily read from ground
level. The first set of contacts shall indicate a low-level alarm condition. The second set of
alarm contacts shall indicate a low-low level trip condition.

7.3.13.3 Thermometer

The thermometer shall be of the electronic type with a remote sensing element located in the
region of the hottest oil. The dial shall be mounted on the transformer tank approximately 1.56
m above the base of the transformer. The thermometer shall be provided with a peak-
temperature reading and two sets of programmable contacts. The first set of contacts shall
indicate a high-oil-temperature alarm condition. The second set of contacts shall indicate an
extreme high oil temperature to be used for tripping.

Temperature Detectors and Thermal Relays

7.3.14.1 Temperature Detectors

Transformer shall be provided with standard, 100-Ω at 0°C, platinum resistance temperature
detectors (RTD) for monitoring:

 One (1) per phase, for reading the equivalent hot-spot temperature of the transformer
windings, mounted in wells extending into the top or side of the transformer. The wells
shall be independent of the wells utilized for the thermal relay. A heater coil, supplied with
current proportional to the transformer load current, shall be mounted inside the RTD well

Rev. 1 7-8 Ayanunga Hydroelectric Project


Date: 22/02/2016
Electromechanical Water-To-Wire Technical Specifications
Section 7 - Main Power Transformer

for thermal relay and shall be of such a rating that the RTD will be subjected to a
temperature equivalent to that of the hottest part of the transformer windings.

 One (1) for monitoring the main tank top oil temperature.
 One (1) for monitoring the main tank bottom oil temperature.
 One (1) for monitoring the tap changer oil temperature
 One (1) for monitoring the ambient temperature.

The RTDs shall be wired to a digital temperature monitor (DTM) for providing local display of
the temperatures. The DTM shall retransmit these temperature values to the Station Control
System using either 4-20 mA loops or a serial interface (Profibus, Modbus or DeviceNet).

7.3.14.2 Thermal Relays

Replica-type thermal relay or relays to simulate the winding hot spot temperature, mounted
externally on the tank, with adjustable temperature settings and auxiliary relays as required
shall be furnished to operate 2 or more sets of electrically independent, self-resetting contact
circuits, for closing an alarm contact to annunciate when the maximum safe winding
temperature for continuous operation has been reached; and for unit tripping when the
maximum safe operating temperature has been exceeded. The relay shall be responsive to
the combined effects of transformer load current and oil temperature in such a way that its
thermal characteristics correspond to those of the transformer windings.

Conduit, Wiring, and Terminal Cabinet

All control, current transformer, protective device, and signal wiring of the transformer shall be
run in rigid stainless steel conduit to terminal blocks in a centrally located terminal cabinet
mounted on the transformer.

The cabinet shall be accessible and located at a convenient height for servicing. The terminal
cabinet shall be of stainless steel construction with IP67 rating. The terminal cabinet shall be
equipped with a thermostatically controlled space heater to prevent condensation within the
cabinet. The operating voltage of the heaters shall be 230-V, 60 Hz, 1-phase.

Feeding for control and protection circuits shall be 125-V DC current, alarm and indication
circuits shall be 24-V DC and auxiliary power shall be 400/230-V AC three phase, 4-wires,
60IHz current.

All the alarm and control wiring between the cabinet and equipment or instruments mounted
on the transformers shall be non-flammable, multi-strand, rubber insulated, color-coded,
copper wires of 1000-V class. Cables less than 2.5 mm2 cross-section shall not be used.

Cooling System

Cooling system shall be made by natural oil circulation (ONAN).

Rev. 1 7-9 Ayanunga Hydroelectric Project


Date: 22/02/2016
Electromechanical Water-To-Wire Technical Specifications
Section 7 - Main Power Transformer

The transformer shall have complete and separate sections of cooling equipment to permit the
transformer to remain in service with one section of the coolers out of service.

The cooling units shall be suitable for the transformer continuous capacities without exceeding
the specified temperature rise.

The coolers structure shall be such that they shall not be affected or loosened by the vibration
of the transformer.

Oil

The oil for the transformer shall be furnished. It shall be a pure mineral oil refined by a proven
process. The quantity of oil furnished shall be sufficient to fill the tank, conservator, and
radiators to the recommended level plus a surplus of 20%.

The oil shall be low in alkali, sulfur, and other corrosive compounds; and shall contain a
minimum of 0.15% of DBPC inhibitor.

The oil shall meet the requirements of ASTM D 3487 or BS 148 at the destination point. The
Employer may draw samples, in accordance with ASTM/BS sampling methods, of the
delivered oil for testing to determine compliance with these requirements. The Employer may
ask for replacement of the oil shipment if any one or more of these requirements is missed by
a margin considered excessive.

The oil utilized for transformer cooling shall have a polychlorinated biphenyl (PCB) level less
than 1 ppm. The Contractor shall obtain an oil sample directly from the oil delivery container
when it arrives on Site and arrange for it to be tested by an independent body for PCB content.
If the level of PCB content tests to be 1 ppm or above, the Contractor shall replace the oil.
Only after an acceptable oil sample is obtained will the Contractor be allowed to proceed with
filling the transformer with oil.

Certified copies of test reports showing the physical and chemical characteristics of the
insulating oil to be furnished shall be provided.

Nameplates and Markings

The transformer shall be provided with 2 stainless steel nameplates in accordance with
Standards. One nameplate shall be mounted on the inside of the terminal cabinet door, and
the second nameplate shall be mounted on the transformer tank adjacent to the tap changer.
Nameplates shall in English and Spanish. Instruction plates, warning signs and any marking
on the equipment, parts and accessories shall be provided in appropriate locations and shall
be in English.

The details to be shown on the nameplates and markings, and the material to be used, shall
be reviewed by the Employer.

Rev. 1 7-10 Ayanunga Hydroelectric Project


Date: 22/02/2016
Electromechanical Water-To-Wire Technical Specifications
Section 7 - Main Power Transformer

Tools

A complete set of special tools, wrenches, or equipment that may be necessary or convenient
for assembling or disassembling the transformer shall be furnished. Any accessories and/or
appliances that are regularly furnished with this class of apparatus or that are necessary for
satisfactory operation thereof and not specified herein shall also be furnished.

SUBMITTALS
Refer to Clause 2.7.2 - Manuals, Drawings, Diagrams and Information for general
requirements for information submittals.

Basic Design

The following detailed design documents shall be provided in accordance with the
requirements of Clause 2.7.2.1 - Documentation Package A:

a) Drawings
 General arrangement of the transformer, including foundation arrangement, major
outline dimensions and elevations, embedded piping, and control equipment.
b) Documents

 A list of all design codes and standards being used.


 Manufacturing quality control plan.
 Transformer design calculations.
 Type test certificates for the transformer class design.
 Factory test procedures.

Detailed Design

The following detailed design documents shall be provided in accordance with the
requirements of Clause 2.7.2.2 - Documentation Package B:

a) Detail Drawings
 General assembly of the transformer in plan and elevation.
 Foundation arrangement, operating forces and anchor bolts including maximum
operating forces on the foundation.
 Lifting drawing, including recommended strop lengths and, if necessary, spreader bar
details.
 Locations and dimensions of coolers.
 Control panel general arrangement.
b) Schematic Diagrams, including

Rev. 1 7-11 Ayanunga Hydroelectric Project


Date: 22/02/2016
Electromechanical Water-To-Wire Technical Specifications
Section 7 - Main Power Transformer

 Control panel schematic drawings.


 Interface Drawings for Unit control system.
c) Other
 Erection and commissioning quality control plan.
 Protective device settings.

FACTORY ASSEMBLY AND TESTS


General

The transformer shall be completely assembled in the factory and tested, insofar as
practicable. The following measurements and checks shall be made:

 Materials tests.

 Check of the dimensions.

All measurements, computations, and tests shall be made in accordance with IEC 60076.
Each transformer shall be completely assembled at the factory and shall undergo all routine
tests required by IEC 60076. As a minimum, the following tests shall be performed:

Bushings

Each bushing, including spares, shall be given a dry, low frequency withstand test, power factor
test, and production tests. One bushing of each type shall be given the standard, wet, 10
second, low-frequency dielectric withstand test. Bushing current transformers shall be tested
in accordance with applicable Standards requirements.

Transformer Tank and Radiators

The complete transformer tank and radiators shall be pressure tested for leaks as required by
IEC 60076.

The transformer tank shall be pressure tested at the design overpressure.

Ratios

The turn ratios for all positions of the tap changer shall be measured.

Polarity and Phase Relation

The polarity and phase relation shall be tested on the rated voltage connection and the lead
marking checked.

Rev. 1 7-12 Ayanunga Hydroelectric Project


Date: 22/02/2016
Electromechanical Water-To-Wire Technical Specifications
Section 7 - Main Power Transformer

Resistance

The cold resistance of the high-voltage and the low-voltage windings shall be measured. The
hot resistance of the windings shall be measured immediately after the temperature test.

Impedance and Losses

The impedance and load losses shall be determined at full rated load current for each high
voltage tap position for the transformer. A test for transformer zero sequence impedance shall
also be performed.

The no-load loss and current shall be measured.

Temperature Rise

The temperature rise of the transformer shall be determined for that connection that will
produce the highest winding temperature at rated load. The temperature rise of the transformer
shall not exceed the limits specified herein. An infrared scan of the tank, braces, etc. shall be
made during the temperature rise test.

Losses and Efficiencies

The guaranteed transformer losses and efficiencies shall be measured at unity power factor.

Exciting Current and Excitation Losses

The exciting current and excitation losses at 90%, 100%, and 110% voltage shall be measured.

Regulation

The regulation shall be determined for rated MVA at unity power factor and at 0.85 lagging
power factor.

Insulation

The transformer complete with bushings shall be given standard insulation tests to be applied
in succession as listed herein.

 Standard impulse tests on each high voltage winding terminal as follows:


 Reduced full wave (1.2 x 50 μs).
 Full wave (1.2 x 50 μs).
 Standard applied potential test on each high-voltage and low-voltage winding with full
BIL. Neutral shall be disconnected if necessary for high-voltage applied potential tests.
 Standard induced-potential test on all windings.
 Tests on transformer neutral consisting of 1 reduced full wave and 2 full wave tests.
 Sweep frequency response analysis of the windings.

Rev. 1 7-13 Ayanunga Hydroelectric Project


Date: 22/02/2016
Electromechanical Water-To-Wire Technical Specifications
Section 7 - Main Power Transformer

 Polarisation index.
The high-voltage tap changer shall be set on the minimum tap during all dielectric tests.

The following tests required by IEC 60076 shall also be conducted:

 The transformer core and frame insulation shall be tested.


 Determination of capacitances windings-to-earth and between windings.
 Measurement of DC insulation resistance between each winding to earth and between
windings
 Measurement of dissipation factor (tan δ) of the insulation system capacitances.
 Dielectric tests as per IEC 60076-3 Table 1.
Noise

The transformer manufactured shall be completely assembled energized at rated voltage and
frequency at no load and tested for audio sound levels. The average noise level shall not
exceed 65 dBA.

Insulation Power Factor

Each winding of the transformer shall be given a power factor test, and the data shall be
entered on the test records and corrected to 20°C. The purpose of these records is for
reference in future maintenance tests. The power factor of the windings, individually or
combined, when corrected to 20°C shall not exceed 0.5%. If tests indicate power factors in
excess of 0.5%, sufficient evidence shall be provided before the transformer is shipped to
satisfy the Employer that the high power factor is not due to excessive moisture.

Partial Discharge

Partial discharge tests shall be made on the transformer. These tests shall be made at the low-
frequency, insulation-test voltage, and the RIV (radio influence voltage) shall not exceed 100
μV at full induced test voltage. Equipment and general method used shall be in accordance
with IEC or ANSI Standards.

Oil Diagnostic Gas Analysis

Oil diagnostic gas analysis shall be carried out before and transformer tests have been
conducted and again after the tests have been completed. Any variances between the before
and after tests, or between the tests on the individual transformers shall be investigated by the
Contractor and any necessary remedial actions taken.

Instrument Transformers

Instrument transformers shall be subjected to tests in accordance with applicable IEC or ANSI
Standards. Tests shall include:

 Routine accuracy tests and polarity tests for each instrument transformer furnished;

Rev. 1 7-14 Ayanunga Hydroelectric Project


Date: 22/02/2016
Electromechanical Water-To-Wire Technical Specifications
Section 7 - Main Power Transformer

 Dielectric withstand test of 2500-V to ground for one minute on each secondary winding
for each instrument transformer furnished.

The equipment shall be installed, field tested and placed in operation by the Contractor as
directed by the manufacturer’s supervising erectors and test engineers. All necessary
assistance, tools, and facilities required for the supervising erectors and test engineers shall
be provided.

Performance Guarantees and Tests

The Contractor shall perform factory tests in accordance with IEC 60076 to verify that the
transformer Performance Guarantees have been met.

The Contractor shall:

 Demonstrate that the transformer no-load and load losses are no greater than the
guaranteed value.

 Demonstrate that the transformer efficiency at 50%, 75% and 100% of rated full load are no
less than the guaranteed values.

Test Reports

Test reports including data and results of all tests required shall be submitted to Employer’s
review. These reports shall include calculation of losses, efficiencies and regulation rates,
copies of voltage and current oscillograms with magnitude and time calibration.

SPARE PARTS
Specified Spare Parts

The Contractor shall furnish the following Specified spare parts:

 One high-voltage bushing complete with gaskets.


 One set of gaskets as required for covers, tanks, manholes and handholes.
 One set of valves.
 One pressure relief device and relay.
 One set of silica gel
“Set” shall be defined as the quantity required for one transformer.

Mandatory and Optional Spare Parts

The Contractor shall furnish a list of recommended Mandatory and Optional additional spare
parts in accordance with the requirements of Clause 2.28 - Spare Parts.

Rev. 1 7-15 Ayanunga Hydroelectric Project


Date: 22/02/2016

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