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Technical Specifications
1.
2.
3.
3.1. SCOPE
This specification covers the design, manufacture, supply, delivery, testing and performance requirements of POWER TRANSFORMERS for the
following Substations:
· Fig tree Substation
1 x 16MVA, 88-132/33kV transformers with online tap changers specified for an 88kV primary voltage.
· Roma Substation
2 x 25MVA, 132/11kV Transformer with an online tap changer.
· Chibombo Substation
2 x 30MVA, 88-132/33kV transformers with online tap changers specified for an 88kV primary voltage.
3.1.1. General Requirements
The supplier will take the following into consideration for the complete design and must provide with his offer explanations of the influence thereof:
· The effect of the difference in height above sea level for the manufacturing plant and the site of installation on the design.
· The effect of the difference in maximum/minimum and yearly average temperatures between the manufacturing plant and the site of
installation on the design.
Manufacture, testing before shipment, all transport & delivery of the new transformers to various substation locations in Lusaka Zambia. The rates
provided must make provision for all loading, off-loading, insurances against loss and/or damage, import duties, taxes and logistics within the time
specified. Tap Change Control Panels does NOT form part of the scope of supply.
Transformers shall comply with the requirements of IEC 60076. Check this std.
Transformers of the same rating shall have matched impedances to allow parallel operation.
A copy of the transformer manufacturer's certificate of quality assurance, issued by an acknowledged institution, shall accompany the Tender.
Provision shall be made for a set of two HV current transformers and one neutral current transformers on the transformer HV and Neutral bushings
respectively.
Specification / Title
Standard Number
IEC 60076 Power Transformers
IEC 60137 Insulated bushings for alternating voltages above
1000V
IEC 60214 On-Load Tap Changers
IEC 60296 Specification for unused mineral insulating oils for
transformers and switchgear
IEC 60529 Degrees of protection provided by enclosures
3.3. general
3.3.1. Type of Transformers
All transformers shall be double wound and be either of the core or shell type. Transformers shall be suitable for outdoor use and shall have
protection classification IP54W (IEC 60529). IEC 60076 recommendations shall be followed.
All transformers shall be fitted with bushings which satisfy the requirements for creepage distance and for impulse levels for altitudes up to 1600 m,
such that transformers can be interchanged one with another at any site.
3.3.2. Electrical Connections
Unless otherwise approved, the direction of winding of the higher and lower voltage windings shall be such that they are of subtractive polarity.
When specified in the Technical Schedules, tappings shall be provided on a three-phase set of transformer windings to provide an alternative ratio of
transformation. The transformer shall be capable of delivering the rated power when connected for the alternative ratio and the unit must be capable
of withstanding the specified voltage tests when connected for the most severe condition.
3.3.3. Duty Under Fault Condition
Except where modified below, it is to be assumed that the amount of generation simultaneously connected is such that normal voltage will be
maintained on one side of any transformer when there is a short circuit between phases or to earth on the other side.
Any transformer may be directly connected to an underground or overhead transmission circuit and switched into and out of service together with its
associated transmission circuit.
All transformers shall be capable of withstanding for three second without damage an external short-circuit between phases. Transformers without
tertiary windings shall be capable of withstanding a short circuit between one phase and earth.
Transformers with tertiary windings shall be capable of withstanding for three second without damage any short-circuit to earth with the neutral points
on both HV (132/88)kV and MV (33/11)kV windings directly connected to earth.
3.3.4. Cores
The cores, framework, clamping arrangement and general structure of the transformers shall be of robust design capable of withstanding any shocks to
which the transformers may be subjected during transport, installation and service.
The magnetic circuit shall be of cold rolled grain orientated steel and the flux density shall be between 1.65...1.75 Tesla when the voltage applied to
any tapping is not in excess of that for which the tapping was designed.
All reasonable care shall be taken in the design and construction of the transformers to reduce noise and vibration to a minimum. Each core shall be
earthed to the tank and securely fastened to prevent movement relative to the tank. Suitable hooks shall be provided to allow for the lifting of the core
from the tank.
The framework and core bolts shall be efficiently insulated from the core so as to reduce circulating current to a minimum.
The core shall be earthed at one point only by means of a link or bolted connection which must be located in an accessible position requiring the
minimum amount of oil to be drained from the tank.. Preferably the link shall be brought out through a separate bushing and earthed through
removable link for inspection purpose.
3.3.5. Windings
The windings shall be fully insulated for continuous working at the specified service voltage.
The insulation of windings and all connections shall be of approved materials which shall not deteriorate under the action of hot oil or from other
causes when the transformers are operated continuously at the maximum permissible loads.
The windings shall be braced in an approved manner to withstand the effect of short circuit and shocks which may occur during transport.
3.3.6. Tertiary Windings
The product of the number of turns of the tertiary windings and the cross-sectional area of one such turn shall not be less than 33% of the
corresponding product for the untapped main winding. Facilities shall be provided for earthing the tertiary winding external to the tank.
3.3.7. Tanks
The tank (including the tank lid) of each transformer shall be of mild steel plate of sufficient thickness to withstand static pressure up to 130 kPa.
Each tank shall be designed to prevent the collection of moisture on any part and shall be sufficiently rigid to prevent distortion when the transformer
is lifted complete with oil and subject to the rigors of road and sea transport.. Suitable lugs shall be provided for this purpose and tank cover shall also
be provided with lifting eyebolts.
Inspection openings shall be provided in the tank cover to give access to changeover links, bushing core earth links etc. and these inspection covers
shall not weigh more than 25 kg each.
Bidders may offer transformers enclosed within a tank incorporating corrugated metal walls and/or ends. The base and tops of such transformers shall
be of mild steel plate having minimum thickness of 5 mm.
Tank covers shall be provided with lifting lugs or lifting eyebolts.
The corrugated wall and ends of the tank shall be formed by folding and welding of the sheet steel of a minimum thickness normally not less than 1.2
mm..
The steel used in the formation of corrugated walls and ends shall comply with BS 4360 or corresponding ISO standard and must be of a quality
suitable for deep drawings not prone to work hardness and accepting the welding processes used in the tank manufacture. The manufacturing process
used shall not introduce any permanent elongation within the steel. Stretching of the walls of the corrugations is not acceptable.
The complete tanks shall be pressure tested for oil tightness and tank rigidity and strength. Such testing shall be completed and proven satisfactory
before the core and windings are installed. The methods of construction testing and quality control of the tanks shall be subject to the approval of the
Engineer at all stages of construction.
The Bidder shall submit comprehensive details of the methods of construction and testing procedures employed and shall be prepared to demonstrate
to the Engineer the complete operation.
The Bidder shall submit details of previous experience in the manufacture of corrugated tanks and shall indicate the number of years manufacturing
corrugated tanks, the number and ratings of the transformers, the site location and the failure rate due to the tank defects.
Details shall be submitted of the standard method of packaging employed to protect the transformers from mechanical damage during transportation to
site. The Bidder shall indicate in detail what additional packing will be provided to protect the transformer during shipping by sea and road and
handling on sites due consideration being given to the limited resources available en route. The method of packaging shall be to the approval of the
Engineer.
3.3.8. Accessories
Each transformer shall be fitted with the accessories specified in the Schedules.
3.3.9. Earthing Terminal
Stainless steel or a mild steel earthing flag approximately 63 mm square and a thickness not less than 6 mm with a centre hole of 14 mm diameter
shall be welded externally to the tank.
3.3.10. Lifting Lugs
Lifting lugs shall be designed to lift the completely assembled transformer with oil.
3.3.11. Jacking Pads
Not less than four suitably and symmetrically placed jacking pads shall be provided in positions, which will not be impeded when the transformer is
loaded on to the transport vehicle.
Each jacking pad shall be designed to support at least half of the total weight of the transformer base and complete with oil the unimpeded working
surface of the jacking pads shall be as follows:
· Minimum/maximum height of jacking pad above base in mm: 460/530.
· Unimpeded working surface mm: 230 x 230.
3.3.12. Skid Under-Base
Skid under-base shall be reinforced to permit moving the transformer in the direction(s) specified. Hauling eyes shall be provided on the under-base.
3.3.13. Oil
Each transformer shall be supplied with a sufficient quantity of oil suitable in all respects for continuous service under tropical conditions. The oil
shall be of approved grade and comply with IEC 60296 Cl I or II.
3.4. Dual ratio transformers
3.4.1. 132-88/33 kv transformers
When requested, facilities shall be provided for changing the voltage for the higher voltage winding from 88kV to 132kV and vice-versa with the
transformer disconnected from the supply system.
3.4.2. On-Load Tap-Changers
On-load tap changing equipment shall be provided of the high speed transition resistor type for varying the transformation ratio whilst the transformer
is on load and without producing phase displacement.
The variations shall be made in steps not greater than those specified over the total range specified without phase displacement.
The taps shall be arranged on the windings specified in the schedules.
The taps shall be brought into a separate oil filled compartment with connection links and bridges so that in no case can tap positions be short
circuited.
Details of the system shall be indicated on an instruction plate mounted on the tap change equipment.
Equipment for local and remote electrical and local hand operation shall be provided and shall comply with the following conditions :
i. It shall not be possible to energise the electric drive when the hand operating gear is in use.
ii. It shall not be possible for the local electric and remote electrical control to be in operation at the same
time and a local/remote changeover switch shall be provided for this purpose.
iii. Operation from the local or remote control switch shall cause one tap movement only unless the control
switch is returned to the “off” position between successive operations.
iv. All electrical control switches and the local operating gear shall be clearly labelled in an approved
manner to indicate the direction of rotation.
v. The local control switches shall be mounted in the Marshalling Kiosk or the control panel.
vi. The control equipment shall be so arranged as to ensure that when a tap change has been started it shall
be completed independently of the operation of the control relays or switches. If the failure of the auxiliary supply during a tap change or any other
contingency would result in that movement not being completed approved means shall be provided to safeguard the transformer and its auxiliary
equipment.
vii. The supply available for electrical operation of the control and indication equipment shall be as stated in
the schedules.
Apparatus of approved type shall be provided:-
i. To give indication of the transformation ratios in use on each transformer both at the local and remote
control points.
The indicators shall show clearly the actual tap position and voltage ratio in use at any time and shall show simultaneously the number representing
this ratio. The number shall range from 1 upward depending on the number of ratios and size of position and shall show the total number of positions
specified. Number 1 shall be the tapping position corresponding to the maximum number of 132kV or 88kV winding turns (i.e. the plus percentage
position). The highest number shall represent the tapping position corresponding to the minimum number of 132kV or 88kV winding turns (i.e. the
minus percentage position). The accuracy of indication of these devices shall not be affected by a variation from plus 15% or minus 15% of the
normal applied voltage
ii. Indication will be given at the remote control point that a change of ratio is in progress by illuminated
signal and buzzer type alarm both to continue energised if a change is not completed.
iii. To make the equipment suitable for supervisory control and indication a multi-way make-before-break
type switch shall be provided at the transformer having one fixed contact for each tap position. This switch shall be provided in addition to any that
may be required for the purpose of remote tap position indication. Supervisory indication shall also be provided in the form of contacts to close on
“Tap Change Incomplete”.
Any switches forming part of the main tap changing apparatus shall be oil immersed and readily accessible. It shall not be possible for the oil in those
compartments which contain contacts used for making and breaking current to mix with the oil in any other compartment.
The tap-changing switches and mechanism shall be mounted in oil tanks or compartments placed in an accessible position on the transformer tank and
shall be supported from the main tank or its base. Drop down oil tanks which necessitate the provision of pits in the foundations shall not be used.
Any “drop down” tanks associated with the tap changing apparatus shall be fitted with guide rods to control the movement during lifting or lowering
operations. The guide rods shall be so designed as to take support of the associated tank when in the fully lowered position. Lifting gear fitted to
“drop down” tanks shall include an approved device to prevent runaway during lifting and lowering operations.
Any enclosed compartment not oil-filled shall be adequately ventilated to restrict condensation. A metal-clad heater shall be provided in the driving
mechanism chamber. All conductor relay coils and other parts shall be suitably protected against corrosion or deterioration due to condensation.
The oil in the compartments of the main tap changing apparatus which do not contain contacts used for making breaking current shall be maintained
under conservator head by means of a pipe connection from the highest point of the chamber to the conservator. This connection shall be controlled
by a suitable valve and shall be arranged so that any gas leaving the chamber will pass into the gas and (oil) actuated relay.
It shall not be possible for the oil in those compartments of the tap change equipment which contain contacts used for making or breaking current to
mix with the oil in the main transformer or to mix with the oil in the compartments containing contacts not used for making or breaking current.
When a conservator is provided and used to maintain oil level in compartments which contain contacts used for making and breaking current it shall
be clearly separate from the main transformer conservator. An oil gauge and a silica-gel breather shall be fitted to each such conservator.
Each compartment in which the oil is not maintained under conservator head shall be provided with an oil gauge of approved design.
Limit switches shall be provided to prevent over-running of the mechanism and shall be directly connected in the circuit of the operating motor. In
addition a mechanical stop or other approved device shall be provided to prevent over-running of the mechanism under any condition.
Limit switches may be connected in the control circuit of operating motor provided that a mechanical declutching mechanism is incorporated.
Thermal devices or other approved means shall be provided to protect the motor and control circuits. All relays, switches fuses, etc. shall be clearly
marked to indicate their purpose. Switches for the initiation of a tap change shall bear the inscription “Raise Tap Number” or “Lower Tap Number”.
Tripping contacts associated with any thermal devices used for the protection of voltage control equipment shall be suitable for making and breaking
150 VA at voltages ranging from 30 V to 230 V a.c. or d.c. and for making 500 VA between the limits of 110 and 250 volts d.c..
A device shall be fitted to the tap changing mechanism to indicate the number of operations completed by the equipment.
The whole of the apparatus shall be of robust design and capable of giving satisfactory service without undue maintenance under the most severe
conditions likely to be met including frequent operation.
A permanently legible lubrication chart shall be fitted within the driving mechanism chamber.
3.6. radiators
Radiators fitted direct to the vertical walls of tanks shall have valves of an approved design top and bottom so that the radiators can be removed when
the tanks are full of oil. Means shall be provided for draining the radiators separately. Radiators shall be suitable for the attachment of fans at a later
date if required. Radiators shall be hot dip galvanised to ensure withstand against corrosion.
3.7. conservator vessels and breathers
A conservator vessel fitted with a sump and suitable means of drainage shall be provided on each transformer and an approved breathing system shall
be supplied.
The oil pipe connection to the conservator shall be of approved design and shall be connected to the highest point or points in the oil system of the
transformer tank before passing to the conservator so that all gas rising from the transformer shall pass into the oil pipe towards the conservator.
The conservator shall have a capacity between the highest and lowest visible levels of not less than 10.5 % of the total cold oil volume of the
transformer and cooling equipment.
A separate conservator vessel shall be provided for the tap changer having a suitable means of drainage and an approved breathing system.
An oil level indicator shall be fitted to each conservator.
3.8. gas and oil actuated relay
The surge float contacts shall close at a rate of steady oil flow between the following limits. As far as possible the limits shall also be met when the
relay is subjected to oil surge conditions produced by rapid opening of a lever operated gate valve.
A test facility will be provided by means of a pushbutton to operate the alarm and trip contacts for test purposes.
Equipment
Minimum Details. (To Be
A.1.2 DESCRIPTION
Requirements Completed By
Contractor)
c Impedance at nominal tap (132kV) 10%
e HV Winding connection configuration 88kV
Short Circuit Current Withstand (kA for
f Specify
3s)
g Noise Level (dB) Specify
j No Load Losses (kW) Specify
j Load Losses @ 75˚C (kW) Specify
j Power Required for Cooling equipment Specify
t Altitude 1600m
Seismic Hazard ( ground acceleration)
t Low(0.2-0.4m/s²)
Attached