MESP TECHNICAL SPECIFICATION FOR A 3.3kV/400V TRANSFORMER FOR USE IN THE ESSENTIAL SERVICES DISTRIBUTION SYSTEM

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1 Engineering Specification Electrical Networks TECHNICAL SPECIFICATION FOR A 3.3kV/400V Version: 1 Issued: September 2016 Owner: Head of Engineering - Electrical Approved By: Andrew Russack Head of Engineering - Electrical PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION

2 Approval Amendment Record Approval Date Version Description 23/09/ Initial issue under MTM. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 1 of 13

3 Table of Contents 1 Purpose Scope Abbreviations Definitions References & Legislation General Standards MTM Documents Background General Requirements Operating Conditions Service Conditions Electrical Conditions Ratings Windings and Connections Construction General Terminals Enclosure Indoor Transformer Transformer Mounted Outdoors Size Labelling Testing Type Test Routine Tests Test Certificates Warranty Maintainability Packaging and Delivery Particulars to be Provided by Manufacturer PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 2 of 13

4 1 Purpose To define the requirements for the selection of a three phase dry type cast resin transformers for use in supplying Essential Services loads within the Melbourne metropolitan railway network. This specification covers transformers with a primary voltage of 3.3 kv and a secondary voltage of 400V to supply Essential Services as defined in L1- CHE-SPE Scope This document applies to the supply of a power transformer for use where three phase loads are to be fed from the Essential Services Power Distribution System as specified in L1-CHE-SPE Abbreviations AC Alternating Current Hz Hertz kv kilo Volt MEN Multiple earth neutral system in accordance with AS/NZS 3000 MTM Metro Trains Melbourne Pty. Ltd. V Volt 4 Definitions For all technical terms refer to AS Shall Should Essential Services Dry-type Transformer Primary Winding Primary Tapping Secondary Winding Is used as the descriptive word to express a requirement that is mandatory to achieve conformance to the standard. Is used as the descriptive word to express a requirement that is recommended in order to achieve compliance to the standard. should can also be used if a requirement is a design goal but not a mandatory requirement. A number of railway services considered essential to the running of trains or public safety including signalling and CCTV. A transformer of which the magnetic circuit and windings are not immersed in an insulating liquid. The winding that receives the active power from the supply system, usually the winding having the highest rated voltage. The tapping to which the rated quantities are related. The winding that delivers the active power to the load circuit, usually the winding having the lowest rated voltage. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 3 of 13

5 5 References & Legislation 5.1 General All materials and components shall comply with the relevant Australian Standard or, where these do not exist, with the relevant IEC or EN Standard. Reference to all standards shall be read as a reference to the latest edition of that standard and amendments available at the time of tendering. The transformer shall meet all relevant Environmental Acts, Legislation and Regulations, Codes of Practice and Standards, and shall be designed to minimise the impact on the environment. Accordingly the transformer shall minimise its environmental impact over its entire asset life cycle, including construction, ongoing operation and disposal. In particular, MTM has a focus on reduced electrical losses in its electrical systems. 5.2 Standards The following standards should be referenced in design and manufacture of the transformer as a minimum: AS 2067 Substations and high voltage installations exceeding 1kV a.c. AS 2374 (all parts) AS 2629 AS 2700 Power Transformers Separable insulated connectors for power distribution systems above 1kV Colour standards for general purposes AS (all parts) Power Transformers AS/NZS Insulated bushings for alternating voltages above 1000V. AS AS Degrees of protection provided by enclosures (IP Code) HV Switchgear and control gear Dimensional standardisation of terminals PTV Infrastructure Drafting Standard 5.3 MTM Documents L1-CHE-SPE-154 L1-CHE-SPE kV Essential Services Distribution System Technical Specification for Automatic Control and Indicated Fixed Mounted Trackside Switchgear for Essential Services Purposes PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 4 of 13

6 6 Background The 3.3kV/400V Transformer provides HV power for three phase loads fed from the MTM Essential Services Power Distribution Network. This system is generally designed as an AC ring main network with a number of trackside location boxes containing step-down transformers. The type of Essential Services (Signal) Power Distribution Network is dependent upon location, and this type of transformer is suitable only for the 3.3kV, three phase application. 7 General Requirements The transformer shall comply with the AS in as far as it applies. The transformer shall be designed and manufactured to give the highest level of reliability whilst requiring the minimum level of maintenance under continuous operating conditions. The transformer shall be a three phase, double wound metal clad, natural air cooling type, with rated output specified, to operate from three phase, 50 Hz, 3.3kV supply with a temperature rise not exceeding 55 C. The transformer shall be of the dry or cast resin type. The transformer shall be designed and manufactured for an operational life in excess of 35 years. 8 Operating Conditions 8.1 Service Conditions The operating conditions in AS shall be applied except that the maximum ambient temperature shall be taken as 45 C. The air may be slightly polluted by dust. The installation conditions shall be specified in the scope document as one of the following: Transformer mounted on the floor inside a building or suitable annex Transformer mounted on the base of inside an appropriately sized stainless steel cabinet installed outdoors. Transformer mounted outdoors on a concrete plinth. 8.2 Electrical Conditions Supply to the primary winding of the transformer will be taken via an ACCB or Fuse Switch from the 3.3kV three phase unearthed Essential Services Power Distribution Network. The secondary winding will be connected to a 400V switchboard, connected to various loads. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 5 of 13

7 9 Ratings The transformer shall meet or exceed the following ratings in accordance with the relevant part of AS Phases 3 Rated Primary Voltage Rated Secondary Voltage Typical Rated Power (to be specified at time of ordering) Rated Frequency Earthing of secondary Primary highest voltage for equipment Secondary highest voltage for equipment Primary rated short-duration power frequency withstand voltage Primary rated lightning impulse withstand voltage Secondary rated short-duration power frequency withstand voltage Secondary rated lightning impulse withstand voltage Maximum Sound Power Level Winding Vector 3300 V 400V 6kVA / 10kVA / 20kVA / 31.5kVA 50Hz Earthed 3.6kV 1.1kV 10kV r.m.s. 20kV peak 10kV r.m.s. 20kV peak Reduced limit in accordance with AS Dyn pf 4% Maximum in-rush current In selecting the rated power, the following criteria shall be adhered to: Anticipated future loadings shall be included in calculations. 8 times full load current The standing load shall not exceed 75% of the transformer rated power; and The sum of the transient load and standing load shall not exceed 95% of the transformer rated power; and The transformer rated power shall be selected from the R10 series, as per AS Due consideration shall be given to the supply capacity of the Essential Services Distribution System prior to the installation of any new transformers. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 6 of 13

8 10 Windings and Connections Five output taps on the primary windings shall be provided for the following range: +5.0%; +2.5%; 0%; -2.5%; -5.0%. The selection of the tapping shall be off-load. The tap changing device shall have a continuous rating of 100% of the Transformer full load current. The tap position shall be selected by moveable connection links located on each of the primary windings. Each of these links shall be constructed from a single section of suitable conductor and shall be capable of making all five tap settings. Alternative arrangements may also be considered acceptable. All insulation used in the transformers shall be non-hygroscopic and designed to withstand continuously a temperature of one hundred degrees centigrade. After winding, the completed coils shall be thoroughly impregnated with an insulating compound under the vacuum process in accordance with AS The composition of the insulating compound shall be such that it will not soften or ooze out under the continued exposure to the maximum working temperatures. None of the materials used shall disintegrate under the continued action of heat and shall not carbonise, become brittle or lose their flexibility, with the maximum working temperatures. 11 Construction 11.1 General The core, framework, clamping arrangements and structure of the transformers shall be of substantial design so as to form a rigid construction entirely unaffected by ordinary handling during transit and installation. All nuts, bolts and pins shall be locked in position so as not to work loose in handling and practice Terminals The primary terminals shall be brought out to approved plug in bushings suitable for the connection of 35mm 2 cable in accordance with L1-CHE-SPE-148, rising from beneath the transformer. The primary terminals shall either be located fully within the transformer enclosure, or shall be protected from unauthorised access by a padlockable panel, able to be secured by a padlock with a 10mm shank. The secondary terminals shall be brought out and enclosed in a suitable polycarbonate box mounted on the transformer. Terminal studs of suitable size to accommodate crimp lugs for up to 25mm² cables (minimum stud size M8) shall be provided within the polycarbonate box. The transformer frame shall be directly connected to an appropriate earth. Two pre-drilled M8 holes shall be provided on opposite sides of the transformer enclosure for this purpose. All terminals shall be legibly and durably marked using characters at least 10mm high. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 7 of 13

9 11.3 Enclosure The required transformer enclosure shall depend on the installation conditions specified in the scope of works document (refer section 8.1) Indoor Transformer The enclosure of the transformer shall be of un-corrugated welded sheet metal not less than 3mm thick. It shall be IP22 rated in accordance with AS 60529, and arranged to stand on channel iron. The Enclosure shall either: be constructed of stainless steel, or be constructed of carbon steel and properly prepared in accordance with AS 1627 prior to the application of protective primer to AS and paint to AS The final colour coat shall be storm grey as described by AS 2700S:2011 (N42). The transformer enclosure shall have a top cover arranged such that it can easily be removed when the transformer is in position connected ready for working, but will prevent the ingress of foreign substances Transformer Mounted Outdoors 11.4 Size The Transformer shall be enclosed by a ventilated metallic enclosure cooled by naturally circulated external air. The enclosure shall be suitable for outdoor installation and of welded stainless steel construction Both primary and secondary terminals on transformers designated for outdoor installation (refer section 11.2) shall be located within the transformer enclosure. Cables shall enter the enclosure through non-ferrous gland plates on the base of the enclosure. The enclosure shall provide a minimum ingress protection of IP 43, in accordance with AS Each enclosure door (where fitted) shall be adequately connected to the main enclosure by copper earth braids, one located at the top and the other at the bottom of each door. The enclosure shall provide padlocking facilities suitable for padlocks with a minimum 10mm shank. The enclosure shall be signed Danger High Voltage on each door. The transformer and enclosure shall be as compact as possible, and in particular, shall occupy a minimum total floor area, preferably no greater than 750 mm x 600 mm, inclusive of any terminals Labelling The transformer shall be provided with a rating plate complying with the requirements of AS The tap link connections and positions shall be clearly shown on the rating plate The rating plate shall be constructed of stainless steel and shall be securely riveted to the top of the transformer. Recorded information shall be physically etched, embossed or engraved clearly onto the surface of the rating plate and shall be highlighted with black paint. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 8 of 13

10 A separate label with the words 3.3 kv/400v Essential Services Transformer shall also be attached to the top of the transformer, with letters not less than 15mm high. In addition, a Danger High Voltage sign conforming to AS 1319 shall be fixed, either to the transformer enclosure, or to the panel protecting the primary terminals if fitted. 12 Testing 12.1 Type Test A Type Test Certificate from a design which is representative of the Transformer to be supplied shall be provided with the Tender documentation Routine Tests Each transformer shall be subjected to a series of inspections and tests to ensure that it conforms to the requirements stated in this specification. The manufacturer shall perform all routine tests as described in Clause 10 of AS :2005 on the Transformer at the manufacturer s factory. MTM reserves the right to appoint a representative to witness these tests. Seven working days notification shall be given to MTM of intention to carry out factory testing Test Certificates The results of the inspections and tests are to be submitted in the form of a signed certificate on the manufacturer s company letterhead. The manufacturer shall provide the completed Certificate of Compliance to MTM for approval prior to delivery. The inspection and test records shall be retained by the manufacturer for a period not less than seven years. The certificate shall include but not be limited to the following information:- Certification number and Date of certification Customer s Name and Contract number Purchase order number Date of manufacture Quantity of delivery Unique serial number for individual product or batch code assigned by the manufacturer Date of the inspection and testing Inspection and test results Statement of compliance to certificate that the product meets all the requirements of this specification Name and Signature of the manufacturer s management representative MTM shall have the right to request supporting Quality Assurance documentation to accompany the manufacturer s Certificate of Compliance. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 9 of 13

11 13 Warranty The manufacturer shall provide warranty to MTM on all items supplied. All goods supplied by the manufacturer shall be guaranteed against faulty workmanship and/or materials for a period of 12 months from the date of commissioning of the equipment or 24 months from the date of delivery, whichever is the later. The manufacturer shall replace without expense to MTM any part (or parts) of the equipment found to be not in accordance with this specification throughout this warranty period. The manufacturer shall provide the same warranty as above for components bought-in from external suppliers. 14 Maintainability The transformer shall be designed to operate with minimal maintenance during the operational life specified in section 0. Documentation shall be provided in English in both electronic and hardcopy forms. The documentation shall include but not be limited to the following information: Installation and maintenance instructions Technical Maintenance Plan detailing maintenance periodicities / servicing schedules List of any recommended spare parts, detailing price, supplier and procurement leadtimes Test equipment and specialist tools required to install, adjust, fault find and maintain of the equipment. Detailed drawings showing: o o o o o o Construction details of the Transformer including dimensions. Physical layout and arrangement of the components of the Transformer. Mounting requirements for the Transformer. Physical layout and arrangement of the primary and secondary terminals. Drawings of the Transformer Rating Plate and data A connection diagram All drawings must comply with the PTV Infrastructure Drafting Standard and shall be submitted for MTM approval prior to manufacturing. Files shall be provided in both Microstation and PDF formats on compact disk (CD). The Technical Maintenance Plan shall reference appropriate detailed instructions in the maintenance manual, and shall also detail safe disposal procedures applicable for when the Transformer is no longer serviceable (recycling, hazardous waste etc.). Instructions shall also specify the requirements for putting the transformer into long term storage and any additional requirements for putting a unit from storage into service. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 10 of 13

12 15 Packaging and Delivery The transformer shall be individually and securely packed to avoid mechanical damage. All transformers shall be packaged and delivered in a manner such that their subsequent in-service performance remains unaffected. PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 11 of 13

13 16 Particulars to be Provided by Manufacturer Manufacturers shall forward all electrical and physical details of the proposed transformer with quotes. The specification non-conformances shall be clearly specified so concessions can be considered. Manufacturers shall supply the following information with regard to the equipment to be supplied: Compliance Does the Transformer fully comply with this specification? Yes No Is a Type Test Certificate attached? Yes No Is a general arrangement drawing attached? Yes No Rated Power Primary winding (kva) Rated Voltage Primary windings (V) Secondary windings (V) Rated Current Primary windings (A) Secondary windings (A) Rated Insulation Level Primary Power Frequency Withstand Voltage (kv) Primary Impulse Withstand Voltage (kv) Secondary Power Frequency Withstand Voltage (kv) Secondary Impulse Withstand Voltage (kv) Impedance Voltage at Rated Primary Power (%) Efficiency and Performance Efficiency at normal continuous output (%) Efficiency at half continuous output (%) Maximum inrush current (primary winding) (A) Magnetising current (primary winding) (A) Voltage Regulation (%) Iron Loss (at Rated Primary Voltage) (W) Copper Loss (at Rated Primary Current) (W) PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 12 of 13

14 Enclosure Overall Length (mm) Overall Width (mm) Overall Depth (mm) Enclosure material Enclosure thickness (mm) Enclosure finish Clearances in Air Phase to Earth (mm) Phase to Phase (mm) Weight Mass of Core and Windings (kg) Total mass (kg) Tap Changer Manufacturer Type Voltage Rating (V) Current Rating (A) Terminal Details Primary Terminals Manufacturer Type Voltage Rating (V) Current Rating (A) Height above base of enclosure (mm) Secondary Terminals Manufacturer Type Voltage Rating (V) Current Rating (A) Height above base of enclosure (mm) PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 13 of 13

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