SPESIFIKASI TEKNIS
TRANSFORMATOR TENAGA
PT PLN (PERSERO)
BUKU STANDARDISASI
SPESIFIKASI TEKNIS
TRANSFORMATOR TENAGA
PT PLN (Persero)
PT PLN (PERSERO)
TENTANG
MENIMBANG a. Bahwa dalam rangka menjaga ketersediaan dan mutu tenaga listrik di
lingkungan PT PLN (Persero), maka diperlukan sistem penyaluran yang
andal;
b. Balwa sistem penyaluran yang andalsebagaimana dimaksud dalam huruf
a di.atas, sangat dipengaruhi oleh kualitas Transformator Tenaga dan
kondisinya sangat beragam di lingkungan pT pLN (persero);
Bahwa untuk menciptakan keseragaman dan keselarasan dalam
pemberlakuan Tnnsformator Tenaga di seluruh unit pr pLN (persero)
y.ang melakukan kegiatan pengadaan Transformator Tenaga, maka perlu
ditetapkan lebih lanjut ketentuan tentang standardisasi spEsifirasi r6knit
TransformatorTenaga di Lingkungan pt ptN (persero);
d. Bahwa berdasarkan pertimbangan sebagaimana dimaisud dalam huruf a, b
9"! " diatas, perlu menetapkan Keputusan Direksi pT pLN (persero)
tgntang stiandardisasi spesifikasi rransformator Tenaga di Lingkungan pi
PLN (Persero); -
13. Keputusan...
13. Keputusan Direksi PT PLN (Persero) Nomor 023.KD1R12012 tentang
Organisasidan Tata Kerja PT PLN (Persero).
MEMUTUSI(AN:
Pasal I
Ketentuan Umum
(1) PLN adalah PT (Persero) Perusahaan Listrik Negara yang didirikan berdasarkan Akta Notaris
Sutjipto, SH Nomor 169 Tahun 1994 beserta perubahannya.
Pasal 2
Maksud dan Tujuan
(1) Maksud Keputusan ini adalah sebagai acuan bagi semua unit di lingkungan PLN yang melakukan
kegiatan pengadaan Transformator Tenaga.
(2) Tujuan Keputusan ini adalah untuk memudahkan proses enjiniring, konstruksi, operasi,
pemeliharaan dan penyediaan material cadang.
Pasal 3
Spesifikasi Teknis Transformator Tenaga
(1) Spesifikasi Teknis Transformator Tenaga adalah sebagaimana tercantum dalam Lampiran I
Keputusan ini.
(2) Spesifikasi Teknis Transformator Tenaga sebagaimana dimaksud pada ayat (1) dapat ditinjau
kembali sesuai dengan kebutuhan.
Pasal 4
Pem berla kuan Spes ifi kas i Tekn is Transformator Tenaga
Spesifikasi Teknis Transformator Tenaga wajib ditraati oleh semua Unit PLN yang melakukan kegiatan
pengadaan Transformator Tenaga.
Pasal 5...
Pasal 5
Ketentuan Penutup
Pada saat Keputusan ini mulai berlaku, maka ketentuan-ketentuan lain yang bertentangan dengan
keputusan ini dinyatakan tidak berlaku.
Ditetapkan di
fada tanggal
S rt'f
{,,{-"
Lampiran I
AiIUDJI
PT PLN (Persero)
Lampiran I
Keputusan Direksi PT PLN (Persero)
Nomor : 0632.K/DIR/2013
Tanggal : 17 Oktober 2013
SAMBUTAN
DIREKTUR UTAMA
Pada kesempatan ini pula, disampaikan terima kasih yang sebesar-besarnya kepada
seluruh anggota TIM Penyusun Buku Spesifikasi Transformator Tenaga PT PLN (Persero)
yang telah bekerja keras dan meluangkan waktu, tenaga dan pikiran untuk menyelesaikan
Buku Standardisasi Spesifikasi Transformator Tenaga ini. Semoga Allah SWT memberikan
pahala dan berkah-Nya kepada seluruh anggota Tim.
Wassalamualaikum Warahmatullahi Wabarakatuh
Direktur Utama
NUR PAMUDJI
TIM PENYUSUN
DAFTAR ISI
1 GENERAL
3 CORE
4 WINDINGS
4.1 Conductor
a. Conductor material high purity copper
b. Conductor manufacturer
- Primary winding ASTA / Metrod / Essex / Shenyang
5.3 Construction :
a. selector switch yes
b. diverter switch & tap selector yes
c. change over selector yes
6 OIL
6.1 Main tank and on load tap changer oil type - Uninhibited Certified Nepthanic
Base
7 TERMINATIONS
8 COOLING SYSTEM :
8.6 Radiator and tube bundle rust protection hot dip galvanized and painting
b. cylindrical/box-type cylindrical
c. Grade of steel to be stated by bidder
10.2 Control and Indication local & remote ; manual & electrical
10.4 Supply voltage for motor of on load tap Vac 230 / 400
changer, fan, and pump
11 PROTECTION
1 GENERAL
3 CORE
4 WINDINGS
4.1 Conductor
a. Conductor material high purity copper
b. Conductor manufacturer
- Primary winding ASTA / Metrod / Essex / Shenyang
- Secondary winding ASTA / Metrod / Essex / Shenyang
- Tertiary winding ASTA / Metrod / Essex / Shenyang
c. Minimum total conductor weight to be stated by bidder
including insulation
d. Winding configuration
- Primary winding disc / helical
- Secondary winding disc / helical
- Tertiary winding multi layer / layer / disc / helical
e. Winding insulation
- Primary winding to be stated by bidder
- Secondary winding to be stated by bidder
- Tertiary winding to be stated by bidder
5.3 Construction :
a. selector switch yes
b. diverter switch & tap selector yes
c. change over selector yes
6 OIL
6.1 Main tank and on load tap changer oil - Uninhibited Certified Nepthanic Base
type
7 TERMINATIONS
8 COOLING SYSTEM :
8.3 Radiator height Higher than main tank with swan neck type
8.6 Radiator and tube bundle rust hot dip galvanized and painting
protection
10.2 Control and Indication local & remote ; manual & electrical
11 PROTECTION
1 GENERAL
3 CORE
4 WINDINGS
4.1 Conductor
a. Conductor material high purity copper
b. Conductor manufacturer
- Primary winding ASTA / Metrod / Essex / Shenyang
- Secondary winding ASTA / Metrod / Essex / Shenyang
- Tertiary winding ASTA / Metrod / Essex / Shenyang
c. Minimum total conductor to be stated by bidder
weight including insulation
d. Winding configuration
- Primary winding disc / helical
- Secondary winding disc / helical
- Tertiary winding multi layer / layer / disc / helical
e. Winding insulation
- Primary winding to be stated by bidder
- Secondary winding to be stated by bidder
- Tertiary winding to be stated by bidder
5.3 Construction :
a. selector switch yes
b. diverter switch & tap selector yes
c. change over selector yes
6 OIL
6.1 Main tank and on load tap - Uninhibited Certified Nepthanic Base
changer oil type
7 TERMINATIONS
8 COOLING SYSTEM :
8.3 Radiator height Higher than main tank with swan neck
type
8.6 Radiator and tube bundle rust hot dip galvanized and painting
protection
10.2 Control and Indication local & remote ; manual & electrical
11 PROTECTION
1 GENERAL
3 CORE
4 WINDINGS
4.1 Conductor
a. Conductor material high purity copper
b. Conductor manufacturer
- Primary winding ASTA / Metrod / Essex / Shenyang
- Secondary winding ASTA / Metrod / Essex / Shenyang
- Tertiary winding ASTA / Metrod / Essex / Shenyang
c. Minimum total conductor to be stated by bidder
weight including insulation
d. Winding configuration
- Primary winding disc / helical
- Secondary winding disc / helical
- Tertiary winding multi layer / layer / disc / helical
e. Winding insulation
- Primary winding to be stated by bidder
- Secondary winding to be stated by bidder
- Tertiary winding to be stated by bidder
5.3 Construction :
a. selector switch yes
b. diverter switch & tap selector yes
c. change over selector yes
6 OIL
6.1 Main tank and on load tap - Uninhibited Certified Nepthanic Base
changer oil type
7 TERMINATIONS
8 COOLING SYSTEM :
8.3 Radiator height Higher than main tank with swan neck
type
8.6 Radiator and tube bundle rust hot dip galvanized and painting
protection
10.2 Control and Indication local & remote ; manual & electrical
11 PROTECTION
1 GENERAL
3 CORE
4 WINDINGS
4.1 Conductor
a. Conductor material high purity copper
b. Conductor manufacturer
- Primary winding ASTA / Metrod / Essex / Shenyang
- Secondary winding ASTA / Metrod / Essex / Shenyang
- Tertiary winding ASTA / Metrod / Essex / Shenyang
c. Minimum total conductor to be stated by bidder
weight including insulation
d. Winding configuration
- Primary winding disc / helical
- Secondary winding disc / helical
- Tertiary winding multi layer / layer / disc / helical
e. Winding insulation
- Primary winding to be stated by bidder
- Secondary winding to be stated by bidder
- Tertiary winding to be stated by bidder
5.3 Construction :
a. selector switch yes
b. diverter switch & tap selector yes
c. change over selector yes
6 OIL
6.1 Main tank and on load tap - Uninhibited Certified Nepthanic Base
changer oil type
7 TERMINATIONS
8 COOLING SYSTEM :
8.3 Radiator height Higher than main tank with swan neck
type
8.6 Radiator and tube bundle rust hot dip galvanized and painting
protection
b. cylindrical/box-type cylindrical
c. Grade of steel to be stated by bidder
10.2 Control and Indication local & remote ; manual & electrical
11 PROTECTION
1 GENERAL
3 CORE
4 WINDINGS
4.1 Conductor
a. Conductor material high purity copper
b. Conductor manufacturer
- Primary winding ASTA / Metrod / Essex / Shenyang
e. Winding insulation
- Primary winding to be stated by bidder
5.3 Construction :
a. selector switch yes
b. diverter switch & tap selector yes
c. change over selector yes
6 OIL
6.1 Main tank and on load tap - Uninhibited Certified Nepthanic Base
changer oil type
7 TERMINATIONS
8 COOLING SYSTEM :
8.3 Radiator height Higher than main tank with swan neck
type
8.6 Radiator and tube bundle rust hot dip galvanized and painting
protection
b. cylindrical/box-type cylindrical
c. Grade of steel to be stated by bidder
11 PROTECTION
1 GENERAL
Primary/Tertiary at 27.8MVA
base
a. At principal tap % 8,5
b. At maximum tap % to be stated by bidder
Secondary/Tertiary at 27.8MVA % 5
base
3 CORE
4 WINDINGS
4.1 Conductor
a. Conductor material high purity copper
b. Conductor manufacturer
- Primary winding ASTA / Metrod / Essex / Shenyang
e. Winding insulation
- Primary winding to be stated by bidder
5.3 Construction :
a. selector switch yes
b. diverter switch & tap selector yes
c. change over selector yes
6 OIL
6.1 Main tank and on load tap - Uninhibited Certified Nepthanic Base
changer oil type
7 TERMINATIONS
8 COOLING SYSTEM :
8.3 Radiator height Higher than main tank with swan neck
type
8.6 Radiator and tube bundle rust hot dip galvanized and painting
protection
b. cylindrical/box-type cylindrical
c. Grade of steel to be stated by bidder
11 PROTECTION
1 GENERAL
3 CORE
4 WINDINGS
4.1 Conductor
a. Conductor material high purity copper
b. Conductor manufacturer
- Primary winding ASTA / Metrod / Essex / Shenyang
- Secondary winding ASTA / Metrod / Essex / Shenyang
- Tertiary winding ASTA / Metrod / Essex / Shenyang
c. Minimum total conductor to be stated by bidder
weight including insulation
d. Winding configuration
- Primary winding disc / helical
- Secondary winding disc / helical
- Tertiary winding multi layer / layer / disc / helical
e. Winding insulation
- Primary winding to be stated by bidder
- Secondary winding to be stated by bidder
- Tertiary winding to be stated by bidder
5.3 Construction :
a. selector switch yes
b. diverter switch & tap selector yes
c. change over selector yes
6 OIL
6.1 Main tank and on load tap - Uninhibited Certified Nepthanic Base
changer oil type
7 TERMINATIONS
8 COOLING SYSTEM :
8.3 Radiator height Higher than main tank with swan neck
type
8.6 Radiator and tube bundle rust hot dip galvanized and painting
protection
b. cylindrical/box-type cylindrical
c. Grade of steel to be stated by bidder
11 PROTECTION
1 GENERAL
3 CORE
4 WINDINGS
4.1 Conductor
a. Conductor material high purity copper
b. Conductor manufacturer
- Primary winding ASTA / Metrod / Essex / Shenyang
- Secondary winding ASTA / Metrod / Essex / Shenyang
- Tertiary winding ASTA / Metrod / Essex / Shenyang
c. Minimum total conductor weight to be stated by bidder
including insulation
d. Winding configuration
- Primary winding disc / helical
- Secondary winding disc / helical
- Tertiary winding multi layer / layer / disc / helical
e. Winding insulation
- Primary winding to be stated by bidder
- Secondary winding to be stated by bidder
- Tertiary winding to be stated by bidder
5.3 Construction :
a. selector switch yes
b. diverter switch & tap selector yes
c. change over selector yes
6 OIL
6.1 Main tank and on load tap - Uninhibited Certified Nepthanic Base
changer oil type
7 TERMINATIONS
8 COOLING SYSTEM :
8.3 Radiator height Higher than main tank with swan neck
type
8.6 Radiator and tube bundle rust hot dip galvanized and painting
protection
10.2 Control and Indication local & remote ; manual & electrical
11 PROTECTION
1 GENERAL
3 CORE
4 WINDINGS
4.1 Conductor
a. Conductor material high purity copper
b. Conductor manufacturer
- Primary winding ASTA / Metrod / Essex / Shenyang
- Secondary winding ASTA / Metrod / Essex / Shenyang
- Tertiary winding ASTA / Metrod / Essex / Shenyang
c. Minimum total conductor weight to be stated by bidder
including insulation
d. Winding configuration
- Primary winding disc / helical
- Secondary winding disc / helical
- Tertiary winding multi layer / layer / disc / helical
e. Winding insulation
- Primary winding to be stated by bidder
- Secondary winding to be stated by bidder
- Tertiary winding to be stated by bidder
5.3 Construction :
a. selector switch yes
b. diverter switch & tap selector yes
c. change over selector yes
6 OIL
6.1 Main tank and on load tap - Uninhibited Certified Nepthanic Base
changer oil type
7 TERMINATIONS
8 COOLING SYSTEM :
8.6 Radiator and tube bundle rust hot dip galvanized and painting
protection
10.2 Control and Indication local & remote ; manual & electrical
11 PROTECTION
TECHNICAL SPECIFICATION
PT PLN (Persero)
Lampiran I
Keputusan Direksi PT PLN (Persero)
Nomor : 0632.K/DIR/2013
Tanggal : 17 Oktober 2013
TECHNICAL SPECIFICATIONS
POWER TRANSFORMER
1. GENERAL
The Work includes design, manufacturing, tests and inspection, packing and
shipping, foundation guide design, guarantee as specified of substation power
transformers including accessories, and the followings if specified: custom
clearance, inland transportation, site assembly and site test.
1.2.1. GENERAL
1.2.2. STANDARDS
Unless specified otherwise or modified herein, all IEC standards (e.g. with the
following series numbers) are directly or indirectly applicable, including parts and
addenda:
1.2.3. CONFLICTS
The equipment shall be suitable for operation under site service condition as
specified in Technical Particulars and Guarantees (TPG).
The equipment will be installed outdoor and will be subject to the minimum and
maximum environmental conditions asspecified in Technical Particulars and
Guarantees (TPG).
The equipment shall be suitable for operation under the ambient conditions
specific to their respective location while in service.
1.5. SUBMITTALS
1.5.1. LANGUAGE
When Bidding
a. Preliminary outline drawings showing dimensions and arrangement/
position of major external features including conservator, terminals, cooling
equipment and other essential appurtenances. These drawings shall show
parts and masses to be removed for transportation.
b. Technical particulars and guarantee
c. Type test certificate for each type of transformers and accessories for the
same rating (Voltage and Capacity) or higher
d. Technical literature on the equipment
e. Satisfactory Operation Statement Letter from users
f. Certificate of ISO-9001 (Latest Version)
g. Quality Manual for Review & Acceptance
h. Other data if requested during evaluation.
2. SPECIFIC REQUIREMENTS
2.1. TYPES AND MAIN PERFORMANCES
The transformers shall be core type, oil immersed, suitable for outdoor installation
and capable for continuous operation without injurious heating when delivering
IEC 60076-5.
2.1.2. LOSSES
The Bidder shall complete the Technical Particulars form, values for components
of losses comprisingnoload loss, load loss at continuous maximum rating (C.M.R.)
and auxiliary loss if any.
The total losses shall be as low as is consistent with transport restrictions,
reliability and economic use of materials.
The Bidder shall state the maximum losses including tolerance. If the losses
measured on test exceed the guaranteed values, then the Contract Price for the
transformer shall be reduced in proportion to the amount by which the losses
measured on tests exceed the guaranteed losses.
The cost of losses:
No-load loss at Rupiah per kW Rp86.063.698,-
Load lossat Rupiah per kW Rp55.080.766,-
Cooling fanat Rupiah per kW Rp21.515.924,-
Any transformer shall be rejected after Factory Acceptance Test (FAT) if the
losses exceed the guaranteed value by an amount in the following:
Total Losses 10%
Component Losses 15% (unless the total loss exceed 10%)
The Bidder shall state in the Schedule of Technical Particulars and Guarantee the
values of impedance measured on principal and extreme tapping and the voltage
regulation from no load to C.M.R. at unity power factor and at 0.8 lagging power
factor with constant voltage across the higher voltage windings.
1. HV Bushing
2. HVN Bushing
3. LV Bushing
4. LVN Bushing
5. TV Bushing
6. Marshalling Kiosk
7. Conservator
8. Tap Changer
9. Tap Changer Motor Drive Unit
10. Radiator
11. Fire Protection
12. Base Plate
3 phase transformer
1 phase transformer
1 phase autotransformer
The design of the magnetic circuit shall be such as to avoid static discharges,
development of short circuit paths internally or to the earthen clamping structure,
and the production of flux components normal to the plane of the laminations.
Each lamination shall be insulated with a material stable under the action of
pressure and hot oil.
The winding structure and major insulation shall be designed to permit an
unobstructed flow of cooling oil through core cooling oil ducts to ensure efficient
core cooling.
The magnetic circuit shall be insulated from all structural parts, and shall be
capable of withstanding a test voltage to core bolts and to the frame of 2500 volts
rms for one minute.
Core shall be constructed of non-aging, high permeability cold rolled grain oriented
silicon steel sheets of the Hi-B or higher grade having minimum magnetic
polarization value of 1.85 Tesla at 800 A/m and maximum specific total loss 0.95 -
1 Watt/kg at 1.7 Tesla and 50 Hz. Adequate evidence for the supply from the steel
sheets manufacturer shall be provided before/during inspection/tests.
The steel sheets shall be properly annealed after cutting to suitable sizes and
rolled to insure smooth surfaces at the edges. Both sides of each sheet shall be
carlite-coated and insulated with heat resisting varnish to minimize eddy current
losses.
The cores shall be carefully assembled and rigidly, strongly enough clamped to
insure adequate mechanical strength to support the windings and to prevent
shifting/displacement of laminations during shipment, transportation, operation,
short circuit or other stresses and also to reduce vibration/noise to a minimum
under operating conditions.
The clamping frames must be insulated against the sheets.
2.2.3. WINDINGS
The transformer windings shall be constructed from high conductivity copper and
assembled in a manner as best suited for the particular application. The
application of ZnO is not allowed in any part of the windings.
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 the free circulation of oil.
Coil 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, and shock during shipment and transportation.
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.
Stabilization treatment for winding stacks shall be made to manufacture windings
All metal parts of the transformer, with the exception of the individual core
lamination, core bolts, and associated individual clamping plates, shall be
maintained at some fixed potential.
The top main core clamping structure shall be connected to the tank body by a
copper strap and the bottom main core clamping structure shall be earthen by one
or more of the following methods:
(a) by connection through vertical tie rods to the top structure.
(b) by direct metal-to-metal contact with the tank base maintained by the weight
of the core and windings.
(c) by connection to the top structure on the same side of the core as the main
earth connection to the tank.
The magnetic circuit shall be earthen to the clamping structure at one point
through a removable link placed in an accessible position just beneath an
inspection opening in the tank cover and which, by disconnection, will enable the
insulation between the core and clamping plates, etc. to be tested at voltages up
to 2.5 kV for the purpose of checking deterioration during service. The connection
to the link shall be on the same side of the core as the main earth connection.
These requirements are compulsory.
Magnetic circuits having an insulated sectional construction shall be provided with
a separate link for each individual section and the arrangement of the connections
shall be subject to the approval of the Purchaser/Engineer.
Where oil ducts or insulated barriers parallel to the plane of the laminations divide
the magnetic circuits into two or more electrically separate parts, the ducts and
insulating barriers which have the thickness greater than 0.25 mm are to be
bridged with tinned copper strips so inserted as to maintain electrical continuity.
Where coil clamping rings are of metal at earth potential, each ring shall be
connected to the adjacent core clamping structure on the same side of the
transformer as the main earth connection.
Main earthing connections shall have a cross-sectional area of not less than 80
sqmm but connections inserted between laminations may have cross-sectional
areas reduced to 20 sqmm when in close thermal contact with the core.
2.3. TANKS
Each transformer shall be enclosed in a suitably stiffened welded steel tank such
that the transformer can be lifted and transported without permanent deformation
or oil leakage. The construction shall employ weldable structural steel.
Lifting lugs shall be provided suitable for the weight of the transformer including
core and windings, fittings, and with the tank filled with oil. Each tank shall be
provided with at least four jacking lugs, and with lugs suitably positioned for trans-
port on a beam transporter. They must be rated for the most unfavourable load
distribution on two diagonals.
The base of the tank shall be so designed that it is possible to move the complete
transformer unit in any direction without injury when using rollers, plates or rails.
Transformers shall have skid bases. Detachable under-bases must not be used.
If wheelbases are requested, the device for fastening the rollers on the rails is part
of delivery. The rails shall also be supplied of the quality at least St 37 and finished
with hot dip galvanization.
All joints, other than those which may have to be broken shall be welded.
Defective welded joints may be re-welded subject to the written approval of the
Purchaser/Engineer.
The transformer shall be provided with a suitable steel tank of substantial
An approved pressure relief device of sufficient size for rapid release of any
pressure that may be generated in the main and OLTC tank, and designed to
operate at a static pressure lower than the hydraulic test pressure specified shall
be provided.
The relief device is to be mounted on the tank cover and means are to be provided
to deflect gas accumulation into the Buchholz relay and not to collect in the relief
device.
The device shall not permit the ingress of moisture. Visible means/alarm shall be
provided for indicating that the relief device has operated. Provision shall also be
added to trip the HV side CB for serious conditions following oil surge.
Pressure relief devices must be full covered with lateral openings for transformer
tank and OLTC. The trip contacts (IP65) must be directly activated by a self-
locking signal pin. Release time must be within 2ms. All important parts like trip
contacts, springs, must be mounted inside.
Main tank:
(a) One 50 mm bore filter valve located near to the top of the tank.
(b) One 50 mm bore filter valve located near to the bottom of the tank and
diagonally opposite to the filter valve required against (a).
(c) One 50 mm drain valve with such arrangements as may be necessary inside
the tank to ensure that the tank can be completely drained of oil as far as is
practicable.
(d) One valve for oil sampling incl. sampling facilities.
(e) Two valves for isolating both sides (in-let & out-let) of each radiator.
(f) One valve for isolating bucholz relay.
OLTC Tank:
(i) Oil drain and sampling facilities.
(j) One valve in oil surge relay pipe-work where appropriate.
Valves shall be of the sluice type, have non-rising spindles and shall be closed by
turning the hand-wheel in a clockwise direction. They shall have machined flanges
and provision for locking in the closed and open positions. Details of the locking
devices shall be clearly shown on the general arrangement drawing.
Every valve shall be provided with an indicator to show clearly the positionof the
valve, and each hand-wheel shall be fitted with a non-corrosive nameplate with
engraved and filled letters or figures to provide an approved inscription which will
indicate the purpose of the valve.
Blank flanges, plates or captive screw caps shall be fitted to all valves and pipe
ends not normally connected in service.
The omission of any of, or the provision of alternative arrangements to, the
aboverequirements will not be accepted unless approved in writing by the
Purchaser/Engineer before manufacture.
All joint faces shall be arranged to prevent the ingress of water or leakage of oil
with a minimum of gasket surface exposed to the action of oil or air.
Oil resisting synthetic rubber gaskets are not permissible except where the
synthetic rubber is used as a bonding medium for cork or similar material or where
metal inserts are provided to limit compression.
Gaskets are to be as thin as possible consistent with the provision of a good seal,
and full details of all gasket sealing arrangements shall be shown on the Plant
drawings.
Two earthing terminals, each capable of carrying the full lower voltage fault current
for a period of not less than 30 seconds, shall be provide. They shall be located
one on either side, and near to the bottom of the transformer to facilitate
connection to the local earthing system.
2.4.1. GENERAL
All radiators shall be detachable and isolating valves shall be provided to allow
removal of radiators with the transformer tank full of oil. The radiators shall be
cleaned and treated in accordance with General Technical Requirements for
finishing.
Radiators shall be designed so that all painted surfaces can be thoroughly cleaned
and easily painted in situ with brush or spray gun. The design is to avoid pockets
in which water can collect. Capability of radiator to withstand the pressure test is
also required.
At nominal power, switching off one blower shall be possible without causing
temperature to rise above permissible values.
Air blowers for use with oil coolers shall be of approved make and design, be
suitable for continuous operation out of doors and shall be capable of dealing with
the maximum output and head required in service. They shall also be capable of
with-standing the stresses imposed when brought up to speed by the direct
application of full line voltage to the motor.
Air blowers shall be complete with all necessary air ducting, and to reduce noise to
the practical minimum, motors shall be mounted independently from the coolers or
alternatively, an approved form of anti-vibration mounting shall be proved.
It shall be possible to remove the blower complete with motor without disturbing or
dismantling the cooler structure frame-work.
Blades shall be of galvanized steel unless otherwise approved. Ducts and Blower
casings shall be made of galvanized steel of thickness not less than 2.6 mm and
shall be suitable stiffened by angles or tees.
Galvanized wire mesh guards shall be provided to prevent accidental contact with
the blades. Guards shall be designed such that neither blades nor other moving
parts can be touched by the test finger illustrated in IEC 60529.
Where multiple fan cooling using small single-phase motors is employed, the
motors in each cooling bank shall preferably be grouped so as to form a balanced
three-phase load.
Each motor or group of motors shall be provided with a three-pole electrically
operated contactor and with control gear of approved design for starting and
stopping manually.
Where forced cooling is used on transformers, provision shall be included under
this contract for automatic starting and stopping from the contacts on the winding
temperature indicating-device as specified in clause 2.6.1. The control equipment
shall be provided with a short time delay device to prevent the starting of more
than one fan, or group of fans in case of multiple-fan cooling, at a time.
Where small motors are operated in groups, the group protection with alarm shall
be arranged so that it will operate satisfactorily in the event of a fault occurring in a
single motor.
The control arrangements are to be designed to prevent starting of motors in total
more than 15 kW simultaneously either manually or automatically.
All contacts and other parts need periodic inspection, renewal, or adjustment shall
be readily accessible.
All wiring for the control gear accommodated in the marshaling kiosk together with
all necessary cable boxes and terminationsand all wiring between the marshalling
kiosk and the motors shall form part of the Contract Works.
2.5.1. GENERAL
The transformers shall be provided with on-load tap changing equipment for
varying the effective ratio while on load, but without producing phase
displacement.
The tap changer shall be connected at the neutral side of HV (primary) winding
and shall be of the high-speed resistor transition type.
On-load tap selectors shall be contained in separate tanks mounted in the main
transformer tank through the top, in an accessible position. The same oil type will
be used as for the main tank.
On-load tap changers shall be suitable for specified power flow in both directions.
All variables and aspects required for reliable operation at site such as step
voltage, breaking capacity, rated through current, voltage class, etc. shall be
fulfilled.
Only design which has been type tested in accordance with IEC 60214 will be
accepted.
The tap selector shall be so arranged as to permit easy access for maintenance
and repair of the equipment thereon, without the necessity of lowering the oil level
in the main transformer tank. Oil in tap selector tanks separate from the main
transformer tank shall be under a slight head of pressure from the conservator
tank and the design shall ensure that any gas formation or air leaving the tap
selector tanks will pass through a protection relay.
Current making and breaking switches integral with the tap selector equipment
Equipment for local (manual & electrical), remote and lockable operation shall be
provided in a suitable weather, vermin, and insect proof cubicle. Electrical remote
control equipment shall also be supplied. The controls shall comply with the
following conditions:
(a) It must not be possible to operate the electric drive when the manual
operating gear is in use.
(b) It must not be possible for two electric control points to be in operation at the
same time.
(c) Operation from the local, remote or supervisory control switch shall cause
one tap movement only unless the control switch is returned to the off
position between successive operations.
(d) It must not be possible for any transformers operating in parallel with one or
more transformers in a group to be more than one tap out of step with the
other transformers in the group.
(e) All electrical control switches and local manual operating gear shall be
clearly labeled in an approved manner to indicate the direction of tap
changing.
The equipment shall be so arranged as to ensure that when a tap change has
been initiated, it will be completed independently of the operation of the control
relays and switches. If a failure of the auxiliary supply during tap change or any
other contingency would result in that movement not being completed, an
approved means shall be provided to safeguard the transformer and its auxiliary
equipment.
Tap changing shall be prevented when the transformer is carrying a load above a
predetermined maximum or when on short circuit. Nevertheless, during switching
the OLTC shall be able to withstand, without damage, the maximum short circuit
current (according to circuit voltage on the HV side) attained by the proper
selection of transformer impedance.
The voltage regulator shall contain at least the following main items:
Match transformer, rms. converter with integrator, limiter stages for higher and
lower, set point adjuster, timing stages for command duration, amplifier, current
compensation, compensation limiting, max. and min. limiter stages, auxiliary vol-
tage transformer.
Voltage drop compensation for the active and reactive voltage component shall be
provided. In addition, the voltage regulators shall be provided with a manual/auto
selector. The regulators will be installed in the separated Remote Regulating Con-
trol Panel in the control room.
Parallel Operation:
If specified in the Schedule of Technical Particulars and Guarantee, the
transformer for each substation shall be designed identical to and able to be
operated in parallel with the existing one.
For transformers to be operated in parallel the control shall permit
independent/master/follower control.
All equipment necessary for this purpose shall be included in the offer/contract.
Open circuit current system, i.e. the coil (relay) is energized when the contact
open. The contacts shall be suitable for use in DC 110 V circuit.
Each transformer shall be provided with 3 (three) approved devices for indicating
the hottest spot temperatures of primary & secondary windings and oil. Each de-
vice shall have a dial type indicator and, in addition, a pointer to register the
highest temperature reached. On each device two separate sets of contracts shall
be fitted, one of which shall be used to give an alarm and the other to trip the
associated circuit breakers. The sets of contacts on the first device shall be
connected in parallel with those on the second device and will be used to activate
the cooling fans.
To simulate indication of the hottest spot temperature of the windings each device
shall comprise a current transformer associatedwith one phase only and a heating
device designed to operate continuously at 130 percent of transformer c.m.r. cur-
rent together with a sensing bulb installed in an oil tight pocket in the transformer
top oil. One CT shall be installed in each winding termination.
The tripping contacts of the winding temperature indicators shall be adjustable to
close between 80 ºC and 150 ºC and to re-open when the temperature has fallen
by not more than 10 ºC.
The alarm and cooling fan contacts shall be adjustable to close between 50 ºC
and 100 ºC and to re-open when the temperature has fallen by a desired amount
between 15 ºC and 30 ºC.
All contacts shall be adjustable to a scale and must be accessible on removal
ofthe cover. alarm and trip circuit contacts shall be suitable for making or breaking
150 VA between the limits of 30 volts and 250 volts ac or dc and of making 500 VA
between the limits of 100 and 250 V dc.
The temperature indicators shall be housed in a tank mounted cubicle and shall be
so designed that it is possible to move the pointers by hand for the purpose of
checking the operation of the contacts and associated equipment.
The working parts of the instrument shall be made visible by the provision of
cut-away dials and glass-fronted covers.
Terminals, links and a 63 mm moving iron ammeter shall be provided in the
marshalling kiosk for each temperature indicator for:
a) Checking the output of the current transformer.
b) Disconnecting the bulb heaters from the current transformer secondary
circuit to enable the instrument to be used as an oil temperature indicator.
A diagram and instruction plate showing the connections of devices and
arrangement of the CT's etc. shall be provided inside the marshalling kiosk.
Maintenance instructions shall be included to show:
i) The heater coil current and temperature indicator reading when the
transformer is operating at CMR with a top oil temperature of 55ºC.
ii) The current injected from an external source and the indicator reading when
the transformer is isolated and when the oil temperature is 20 ºC.
Each transformer shall be fitted with gas and oil-actuated relay (Bucholz relay)
equipment having alarm contacts which close on collection of gas or low oil level,
and tripping contacts which close on following oil surge conditions.
Each gas and oil-actuated relay for main and OLTC oil shall be provided with a
test cock to take a flexible pipe connection for checking the operation of the relay.
To allow gas to be collected at ground level, a pipe shall be connected to the gas
release cock of the gas and oil-actuated relay and brought down to a point
approximately 1.4 m above ground level, where it shall be terminated by a cock
which shall have provision for locking to prevent unauthorized operation.
A straight run of pipe shall be provided for a length of five times the internal
diameter of the pipe on the tank side of the gas and oil-actuated relay and three
times the internal diameter of the pipe on the conservator side of the gas or
oil-actuated relay.
The design of the relay mounting arrangements, the associated pipe-work and the
cooling plant shall be such that mal-operation of the relays will not take place
under normal service conditions.
The pipe-work shall be so arranged that all gas arising from the transformer will
pass into the gas and oil-actuated relay. The oil circuit through the relay must not
form a delivery path in parallel with any circulating oil pipe, nor is it to be teed into
or connected through the pressure relief vent. Sharp bends in the pipe-work shall
be avoided.
The outdoor type bushing insulators shall comply with IEC 60137.
The minimum creepage distance for outdoor bushings shall be very heavy degree
of pollution for coastal and industrial area, while for other locations shall be heavy
degree of pollution (refer to Book A I Clause 1.2).
Bushings shall be of sealed construction, but attention is particularly drawn to the
very humid conditions at Site and in addition, to the very rapid cooling of
equipment exposed to direct sunlight when this is followed by sudden heavy
Cable boxes and sealing end chambers shall be designed to accommodate all the
cable joint fittings or sealing ends required by the manufacturer of cables,
including approved means of controlling the voltage stress of the terminal
insulation of cables.
Oil filled cable sealing end chambers shall be provided with removable links for
testing purposes. The chamber shall have a removable cover and the design of
the chamber is to be such that ample clearances are provided to enable either the
transformeror each cable to be subjected separately to high voltage tests.
The oil level in the sealing end chambers shall be maintained from the main
conservator tank by means of a connection to the highest point of the chamber,
this connection shall be controlled by suitable valves.
A connection to the conservator shall be made so that any gas leaving the
chamber must pass through the gas and oil- actuated relay.
An earthing terminal shall be provided in each disconnecting or sealing end
chamber to which the connections from the transformer winding can be earthen
during cable testing.
The medium voltage cable boxes and disconnecting or sealing end chambers shall
be capable of withstanding for 15 minutes both at the time of the first test on the
cables and at any subsequent time as may be required between phases & to earth
a test of 48 kV dc or 32 kV ac.
During these tests the links in the disconnecting or sealing end chamber or cable
box will be withdrawn and the transformer windings with connections thereto will
be earthen.
All cable boxes and disconnecting chambers shall have oil-tight joints and are to
be tested with oil having a viscosity not greater than that of insulating oil when at a
temperature of 15ºC at a pressure of 6.87 N/sqcm for 12 hours, no oil leakage is to
occur and no permanent deformation is to take place in the structure.
For GIS (if any), facilities shall be provided at the transformer primary/HV side for
terminating single core XLPE Cu (of specified dimension) cables per phase
individually in cable end boxes. The cable end boxes and the transformer bushing
specified shall be interchangeable.
Means shall be provided on the transformer tank side for supporting cables.
All cable boxes shall have oil-tight joints and are to be tested with oil having a
viscosity not greater than that of IEC 60296 insulating oil when at a temperature of
15 ⁰C at a pressure of 69 kN/sqm for 12 hours, no oil leakage is to occur and no
permanent deformation is to take place in the structure.
The disconnecting chamber shall have a removable cover and the design of the
chamber is to be such that ample clearances are provided to enable each cable to
be subjected separately to high voltage tests.
The oil level in the disconnecting chamber shall be maintained from the main
conservator tank by means of a connection to the highest point of the chamber
and this connection shall be controlled by suitable valves. A connection to the
conservator shall be made so that any gas leaving the chamber must pass through
the gas and oil-actuated relay.
An earthing terminal shall be provided in each disconnecting or sealing end
chamber to which the connections from the transformer winding can be earthen
during cable testing.
2.10.3. TESTING
The cable boxes and disconnecting or sealing end chambers shall be capable of
withstanding for 15 minutes both at the time of the first test on the cables and at
any subsequent time as may be required, between phases and to earth a test
voltage equal to:
2E kV DC or an AC test equal to 1.3E kV
Where: E = system voltage between phases in kV(rms).
During these tests the links in disconnecting or sealing end chamber or cable box
will be withdrawn and the transformer windings with connections thereto will be
earthen.
Auxiliary power and multi-core control cables between the all parts/equipment of
the transformer contract (among transformer, marshalling kiosk or tank mounted
cubicle, remote regulating control panel, fire protection system (if any, ancillary
equipment) shall be installed, glanded and have individual cores identified and
terminated under this Contract.
Cables from each transformer scope to auxiliary supply switchboards and
interconnections with other transformers will be supplied, glanded and have
individual cores identified and terminated under this Contract.
Supply of cables shall be of the shielded/armoured type with sufficient dimensions
and subject to approval.
The following typical set of spare parts and other special tools (if any) shall be
proposed separately as optional and to be quoted with appropriate quantity in the
schedule of recommended spare parts in the Bidding Document – Book C:
1. HV bushing
2. LV bushing
3. HV neutral bushing
4. LV neutral bushing
5. TV bushing
6. Gaskets
7. Thermometers
8. Oil level indicators
9. Motor for tap changer
10. Cooling fan with motor
11. Buchholz and OLTC relays
12. AVR incl. voltage regulation relay
13. Magnetic contactors & auxiliary relays
14. Molded-case breaker
15. Contact elements of tap changer diverter switches
16. Valves and plugs
17. Silicagel for dehydrating breather
18. Final coating paint with solvent
19. Each kind of signal lamp
Before filling with oil, the transformer coil assembly, tank, radiators and all internal
parts shall bethoroughly cleaned of all dirt, grease and loose items.
The tank shall be filled from the bottom valve under vacuum conditions with
transformer oil of Uninhibited Certified Nepthanic Base and complying with IEC
60296 for acceptance tests.
Certificate of Mixability Test with Shell Diala B shall be issued by PT PLN
(Persero) PUSLITBANG and shall be submitted with the Bid.
The following suppliers have been pre-approved as acceptable suppliers for the nominated
equipment at the time of preparation of this specification and evidence of satisfactory in
service performance has been proven to the Purchaser’s satisfaction.
Manufacturer who wishes to supply ancillary product which meet the above criteria shall
provide Purchaser with a proposal which contains complete specification, Material Safety
Data Sheet for the product, a statement with assessment of in-service performance and a
reference list of users who can attest to the claimed in-service performance. The proposal
is subject to Purchaser’s approval.
2.15. TESTS
All external components and fittings that are likely to affect the performance of the
transformer during the test shall be in place.
All measuring systems used for the tests shall have certified, traceable accuracy
and be subjected to periodic calibration. The manufacturer shall provide the copy
of calibration certificates before the testing begins.
COMPLETED TRANSFORMER
Routine, type and special tests shall be carried out in accordance with IEC 60076
and summarized as the following:
TEST
PLN ACCEPTANCE
NO TESTS ITEM METHOD
CRITERIA *)
STANDARD
ROUTINE TEST
1 Voltage Ratio and IEC 60076-1 ±0,5% of declared ratio
Phase Displacement (clause 10.3)
Check
2 Winding Resistance IEC 60076-1 -
(clause 10.2)
3 Load Loss and IEC 60076-1 • Load Loss: Max +10% from
Impedance Voltage (clause 10.4 guaranteed value
and 10.7) • ±7,5% of declared
impedance
• Impedance measurement
on all tappings
4 No-Load Loss and IEC 60076-1 • +10% from guaranteed no-
no-load current (clause 10.5) load loss value
• +30% of the declared no-
load current value
5 Harmonics of The IEC 60076-1 Less than the guaranteed
No-Load Current (clause 10.6) value
6 Test on On-Load IEC 60076-1 Sequence of operations shall
Tap Changer (clause 10.8) be performed without failure
7 Measurement of IEEE C57
Insulation
Resistance of The
TEST
PLN ACCEPTANCE
NO TESTS ITEM METHOD
CRITERIA *)
STANDARD
Windings
8 Polarization Index IEEE C57
9 Dielectric Test of -
Core to Earth
10 Separate Source IEC 60076-3 No collapse of the test voltage
Voltage Withstand occurs
Test
11 Short-duration AC IEC 60076-3 • No collapse of the test
withstand voltage (clause 12.3) voltage occurs
test (ACSD), phase-
to-earth test
12 Short-duration AC IEC 60076-3 • No collapse of the test
withstand voltage (clause 12.3) voltage occurs
test (ACSD), phase- • The continuous level of
to-phase test with ‘apparent charge’ at U2
earthed neutral during the second 5 min
(Partial Discharge does not exceed 70 pC on
Test) all measuring terminals
• The partial discharge
behavior does not show a
continuing rising tendency
13 Determination of IEC 60076-1 Tan δ < 0.5%
Capacitances IEEE C57
windings-to-earth
and between
windings, and Tan δ
of The Windings
15 Functional Test of - -
Accessories
16 Dielectric Test of IEC 60076-1 No collapse of the test voltage
Auxiliary Wiring to occurs
Earth
17 Lightning Impulse IEC 60076-3 • The test impulse shall be a
Test full standard lightning
impulse: 1,2 μs ± 30 %/50
μs ± 20 %
• The absence of significant
differences between
voltage and current
transients recorded
atreduced voltage and
those recorded at full test
voltage constitutes
evidence that the
insulationhas withstood the
test.
18 SFRA Measurement -
19 Breakdown Voltage IEC 60156
and Dissipation and IEC
Factor of The 60247
Insulating Oil
20 Dissolved Gas IEC 60599
Analysis
TEST
PLN ACCEPTANCE
NO TESTS ITEM METHOD
CRITERIA *)
STANDARD
21 Oil Leakage / -
Pressure Test
22 Measurement of IEC 60076-1 +10% from guaranteed value
Power Taken by
Fans
23 Measurement of DP > 900, measured on paper
insulation paper DP sample after drying process
value
TYPE TEST
1 Temperature Rise IEC 60076-2 Hot Spot Temperature Rise <
Test 68 K measured by fiber optic
sensor
2 Noise Level Test IEC 60076- Less than guaranteed value
10
3 Measurement of IEC 60076-1
Zero Sequence
Impedance
4 Auxiliary Losses -
5 Vacuum Test -
The tapping connection to be used for the impulse tests shall be the one on which
the highest voltage stresses occur. Verification of the correct choice of tapping
shall be provided. Impulse tests shall be applied by direct application to each line
terminal in turn except where, by agreement with the Engineer, the transferred
surge method of test may be adopted for tests on lower voltage windings.
The tapping connection to be used for the impulse tests shall be the one on which
the highest voltage stresses occur. Verification of the correct choice of tapping
shall be provided. Impulse tests shall be applied by direct application to each line
terminal in turn except where, by agreement with the Engineer, the transferred
surge method of test may be adopted for tests on lower voltage windings.
BUSHINGS:
Routine, type, sample and special tests shall be carried out in accordance with
IEC 60137.
The following special test shall be made:
Short time current test:
Each type of bushing being provided shall be subjected to a short time current test
of 3 seconds at the fault rating specified in the schedule of technical particulars,
the test procedure being in accordance with that of IEC 60056.
Routine test:
Oil tightness - All cable boxes and disconnecting chambers shall be tested with oil,
having a viscosity not greater than that of IEC 60296 insulating oil when at
temperature of 15 °C, at a pressure of 70 kN/m² for 12 hours; during this time no
leakage shall occur nor shall there be any permanent set when the pressure is
released.
Routine tests:
Oil leakage:
All tanks, conservators and oil filled compartments including all forms of radiator
shall be tested, before painting, for oil tightness by being completely filled with oil
of a viscosity not greater than that of IEC 60296 insulating oil at a temperature of
15 °C and subjected to a pressure equal to the normal pressure plus 35 kN/m².
This pressure shall be maintained for a period of not less than 24 hours, during
which time no leakage shall occur.
The tap changer barrier shall be subjected to normal oil pressure head for 24
hours, during which time there shall be no leakage from the panel or bushings.
Type tests:
Unless type test certificates can be produced for test carried out on similar equip-
ment, the following tests shall be done for tank, conservator, radiator and pressure
relief device:
Vacuum test:
The equipment shall be subjected to a vacuum of 508 mm of mercury less than
atmospheric pressure when empty of oil.
Less than1300 mm 3 mm
1300 to 2500 mm 8 mm
Greater than 2500 mm 12.7 mm
Pressure test:
The equipment is to withstand pressure corresponding to normal pressure plus 35
kN/m² for 12 hours.
The permanent deflection of plates or stiffeners on removal of pressure is also not
to exceed the values stated in respect of the vacuum test in the above table.
This test may be combined with a routine oil leakage test.
The tap changer barrier shall be shown to withstand an over pressure test of
normal pressure plus 35 kN/m2 for 12 hours.
For pressure release device, it shall be subjected to increasing oil pressure and
shall operate just slightly before reaching normal pressure plus 35 kN/m². The
operating pressureshall be recorded on the test certificate.
Routine tests:
Air/oil coolers:
All coolers using forced oil circulation shall be filled with oil of a viscosity not
greater than that of IEC 60296 insulating oil at a temperature of 15 °C and
subjected to a pressure equal to twice the maximum working pressure at the inlet
to the cooler under service conditions which shall be maintained for a period of not
less than 24 hours; during this time no leakage shall occur.
Water/oil coolers:
The oil and water compartments of all water cooled oil coolers shall be tested
separately to withstand a hydraulic pressure of 350 kN/m2 for 15 minutes after
which the pressure shall be reduced to twice the maximum working pressure at
the inlet to the cooler under service conditions and shall be maintained for a period
of not less than 24 hours during which time no leakage shall occur.
Type tests:
One forced-oil of each type shall be subjected, when empty of oil, to that vacuum
test level specified. There shall be no permanent deformation or distortion of any
part of the cooler.
Routine tests:
Oil filled equipment:
The bodies of all oil pumps complete with submerged motors, if any, and the oil
pipe work, oil sampling devices and valves shall withstand a hydraulic pressure of
140 kN/m2 for 15 minutes.
Control gear:
All control gear shall be subjected to the tests specified inthe appropriate IEC.
Motors:
Each motor shall be subjected to the following tests where applicable:
- Measurement of winding resistance (cold).
- No load test at rated voltage for determination of fixed losses.
- An overvoltage test at 1.5 times rated voltage applied with the machine
running at no load, for a period of 3 minutes, to test inter-turn insulation.
- High voltage in accordance with IEC 60034.
Type tests:
Motors:
Performance tests shall be in accordance with IEC 60034 however, certificates of
OIL
Sample test:
Sample of oil from each consignment shall be tested in accordance with IEC
60296 before dispatch.
Subject to the agreement of the Engineer a test certificate, confirming that the oil
from which the consignment was drawn has been tested in accordance with IEC
60296, may be accepted. Before commissioning any reactor, the electric strength
of its oil shall be check-tested and the result approved by the Engineer.
between each of the electrical circuits and the casing for one minute, the
remaining circuits being connected to the casing.
Operation:
With the transformer assembled with its cooling plant as in service, tests
shall be made to demonstrate that the relay does not operate whilst the oil
pump motors are being started or stopped.
B. SAMPLE TEST:
At the discretion of the Engineers, the following tests shall be made:
Variation of performance with mounting angle with the mounting conditions
as in service, the mounting angle shall be varied within the rising angle limits
1° and 9° and tests repeated in the manner prescribed for the routine tests.
SECONDARY WIRING:
All secondary wiring, including panel wiring and control circuits and all apparatus
connected thereto shall be subjected to the following tests.
Routine tests:
Voltage: 2.5 kV applied for one minute.
Insulation resistance: By megger of not less than 500 volts.
GALVANIZING:
Sample tests:
Samples selected by the Engineers of all galvanizing materials shall be subjected
to the galvanizing test set out in BS 443- "Testing of Zinc Coating on Galvanized
Wires", or BS 729- "Testing of Zinc Coating on Galvanized Articles other than
Wire", whichever is applicable.
WELDING
Welder’s qualification tests:
All welders engaged on fabrication either in the manufacturer's works or on site
and on any weld repairs subsequently found necessary shall, before undertaking
welding, satisfactorily complete procedure and qualification tests in the presence
of the Engineer.
The minimum requirement for the testing of welders engaged on structural steel
would be as follows:
Butt welds (manual):
Test plates to be of average thickness for the Contract.
Two test required: horizontal/vertical and vertical.
From each test weld made are to be prepared one forward and one reverse bend
test and one macro specimen.
The bend tests are to be taken through 180 degrees over a former of diameter
equal to three times the thickness of the plate.
Fillet welds:
The size of fillet weld must be an average of those called for on the Contract.
Two tests are required: horizontal/vertical and vertical.
From each test weld, nick break and macro specimens are to be prepared.
Butt welds (machine welding):
On full penetration butt welds, the first two seams welded are to be witnessed with
'run on' and 'run off' plates attached.
From these plates are to be prepared a forward bend, a reverse bend and a
macro. The bend requirements are as for the manual test.
On partial penetration butt welds the first two seams are to be witnessed and
macro specimens are to be prepared from the 'run on' and 'run off' plates in
addition to the ends of the actual weld. The extent of penetration is the comply
with the approved drawing.
The Shop Tests shall alsoinclude the followings:
a. Visual checks for completeness of the equipment and accessories
b. Functional tests on all system
c. Interchangeability of removable elements of corresponding rating