SECTION 16320 PACKAGE SUBSTATION

PART 1 - GENERAL 1.1 SECTION INCLUDES A. Furnishing and installation of and testing package substation in accordance with specifications and drawings. Any material or equipment necessary for the proper operation not specified or described herein shall be deemed part of the specifications.

1.2

REFERENCES A. SASO - Saudi Arabian Standards Organization SASO 334 Industrial safety and health regulations Part 7: electric high voltage

B.

IEC - International Electrotechnical Commission IEC 60076-1 to 5 Power transformers IEC 60354 IEC 60439-1 Loading guide for oil-immersed power transformers. Type Tested and Partially type tested Assemblies.

C.

CENELEC Harmonisation Documents: HD 398-1 to 398-5 `+ A3 for power transformers HD 428-1 S1 for three-phase oil-immersed type distribution transformers 50 HZ, from 100 to 2500 KVA with highest voltage for equipment not exceeding 24 KV.

D.

SEC SAUDI ELECTRIC COMPANY All relevant standards

E.

NFPA - National Fire Protection Association NFPA 70 National Electric Code

1.3

SUBMITTALS A. Shop Drawings and Manufacturer's Data: The contractor shall submit to the Engineer for review, detailed dimensioned shop drawings and manufacturer's literature where deviations from the contract drawings or specification exist. Shop drawings and/or data sheets shall be based on information stated in the specifications and as shown on the contract drawings and shall show all pertinent deviations and data for the fabrication and complete installation.

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Manufacturer's data sheets shall be submitted indicating the necessary installation dimensions, weights, materials and performance information. The above information may be provided by standard catalogue sheets marked to indicate the specific items provided. B. Operation and Maintenance Instructions: The contractor shall furnish data covering model, type and serial numbers, capacities, maintenance and operation of each major item of equipment or apparatus in accordance with the requirements of the contract documents. Operating instructions shall cover all phases of control. Test Reports: The contractor shall submit test reports to the Engineer for review. Recommended Spare Parts List: The contractor shall submit recommended spare parts list to the Engineer for review. As Built Drawings: The contractor shall submit the as built drawings to the Engineer for review and approval.

C. D.

E.

1.4

QUALITY ASSURANCE A. All materials and products shall be new, sound and uniform in quality, size, shape, color and texture and shall be free from defects. The work shall be carried out in accordance with this specification, the contract drawings and the standards listed herein. The referenced codes and standards provide an acceptable level of quality for materials and products: The contractor shall be responsible for ensuring that the required standards of quality control as mentioned in relative sections are maintained for the proposed transformers. If requested by the Engineer, the supplier shall provide proof of application of a quality procedure complying with standards. This means: 1. 2. 3. E. Use of a quality manual approved and signed by a management representative, Regular updating of this manual so that it reflects the most recent applicable quality control procedures, ISO 9002 certification.

B.

C.

D.

The manufacturer must have a sound experience in the field of transformers for not less than ten years, and should have a presentable reference list of the already supplied equipment of the same type and same make and that this equipment has been in satisfactory operation in Kingdom of Saudi Arabia for at least three years.

1.5

COORDINATION A. The contractor shall be held responsible for the proper coordination of all phases of the work under this contract.

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B.

It shall be the responsibility of the contractor to coordinate the work and equipment as specified herein with work to be performed and equipment to be furnished under other sections of the specifications in order to assure a complete and satisfactory installation.

1.6

TRANSPORTATION, HANDLING AND STORAGE A. Deliver, store, protect and handle products to site as per manufacturers instructions. Store transformers in clean and dry space. Inspect for damage. Maintain factory wrapping or provide an additional heavy canvas or heavy plastic cover to protect units from dirt, water, construction debris and traffic. Lift only with lugs provided for the purpose. Handle carefully to avoid damage to transformer internal components, enclosure and finish.

B.

C.

1.7

WARRANTY A. Submit written guarantee signed by the contractor and manufacturer for the period of one year from the date of substantial completion. The guarantee shall cover the repair and replacement of defective materials and workmanship as directed by the Engineer.

1. 2.1

PART 2 - PRODUCTS GENERAL A. The following specifications apply to package substations destined for use in three-phase MV/LV distribution systems. Package Substation shall be a compact substation; factory assembled, metal enclosed type with galvanized steel sheet 2.0 mm thick minimum. It should be designed, manufactured and tested in accordance with applicable SASO, SEC and IEC standards including IEC 60439-1. The Substation should be composed of the following compartments, fully segregated by metal partitions and insulating materials with natural type ventilation: 1. 2. 3. 4. A metallic enclosure for outdoor type. Medium voltage compartment (SF6 Ring Main Unit). MV/LV Transformer compartment. LV compartment (Main Distribution Board).

B.

C.

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2.2

TECHNICAL DATA MV TR LV

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Rated power (KVA) as required Rated voltage (KV) 17.5 0.69 Service voltage (KV) 13.8 0.38 Rated frequency (HZ) 60 60 60 Rated insulation level (KV) 38 38 0.75 (Power-frequency for 1 minute withstand voltage) Rated insulation level (KV peak) 95 95 8 (Impulse withstand voltage) Short circuit withstand (sym.) at 20 30 Service voltage for 1 sec. (KA) Busbar rated (A) 630 As shown Degree of protection for compartments IP43 IP23 IP43 HV bushings Plug-in LV bushings Flat bars Vector group Dyn11 Maximum ambient temp.(Deg. C) 50 50 50 Altitude (m) Less than 1000 1000 1000 Daily average temperature between 5 Deg. C and 40 Deg. C and max. Of 50 Deg. C according to IEC. METAL ENCLOSURE A. The metallic enclosure shall comprises of 3 parts such as: 1. 2. A skid base made of U-channel An external envelope including roof shall made of minimum 2 mm thick galvanized steel sheet with 2 doors, one for MV compartment and one for the LV compartment.

2.3

B.

The external envelope including roof shall be factory painted to be painted with two coats enamel paint. The cooling of the transformer compartment shall be natural type ventilation. All the doors of the kiosk shall be fitted with dust proof joints.

C. D. 2.4

MV COMPARTMENT A. It contains a SF6 Ring Main Unit (RMU) ensuring the MV outgoing and transformer.protection functions. The RMU comprises of two 630A load-break switches and one 200A circuit breaker.

B.

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2.5

TRANSFORMER A. Technical Data B. Type Rated power Cooling Standard Thermal Class Max. ambient temperature Dielectric Dielectric temperature rise Winding temperature rise Max. altitude Vector Group Winding material Primary voltage MV rated voltage Power-frequency withstand voltage Impulse withstand voltage - peak MV tapping range (off-voltage) Secondary No-load voltage - For 400V system, No-Load Voltage - For 230V system, No-Load Voltage Frequency Rated impedance voltage MV Terminals LV Terminals : Hermetically sealed : As shown on the drawings : ONAN : IEC 60076 and SASO :A : 50 Degree C : Mineral oil : 50 Degree C : 55 Degree C : 1000 m : Dyn11 : Copper : 13.8 KV : 17.5 KV : 38 KV : 95 KV : 2.5% 5% : 400V : 231V : 60 HZ : 4 to 6 % : Plug-in : Flat-bars

Magnetic Core 1. This shall be made from laminations of grain oriented silicon steel, insulated with mineral oxide; the method of cutting and stacking shall be "step lap", so as to optimize the level of no-load losses.

C.

LV Windings 1. These shall be made from copper profile wire or aluminum or copper foil (according to the manufacturer's preference).

D.

MV Windings 1. These shall be made of copper profile wire or aluminum or copper round wire (according to the manufacturer's preference).

E.

MV Connections 1. 2. The standard MV connections shall use porcelain bushings on the top of the transformer. Fixed MV plug-in bushings, with MV mobile plug-in bushings - straight or elbow according to the orientation of the incoming cables - may be provided if specified in the other documents.

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F.

LV Connections 1. 2. The LV connections shall be made using porcelain bushings up to 200 KVA, and flat-bars from 250 KVA onwards. A LV air-insulated terminal cover may be provided if specified in the documents.

G.

MV Tapping 1. The tapping which act on the highest voltage adapting the transformer to the real supply voltage value, shall be provided with an off-circuit tap-changer switch with a padlocking facility on the top cover of the transformer.

H.

Tank 1. The tank of the transformer shall be made with flexible cooling corrugations, in order to absorb the expansion of the dielectric due to temperature variations. The cover shall be bolted on top of the tank. The tank shall be built in such a way as to avoid any water accumulation.

2. 3. I.

Dielectric and Component Material 1. 2. 3. 4. 5. The dielectric shall be mineral oil, class I & II according to IEC 60296. The concentration in PCB has to be lower than the minimum detection rate of 2 ppm (parts per million). The components of the transformer such as insulation material, varnish, painting, etc. have to be new and PCB-free. The filling of the transformer shall be made under vacuum, in order to guarantee the maximum preservation of dielectric properties. The live part of the transformer shall be previously oven dried so as to remove all residual humidity.

J.

Gaskets 1. All the gaskets shall be resistant against the action of the mineral oil, at the working temperature.

K.

Protection against Corrosion 1. The anticorrosion treatment of the tank and the cover shall comprise: 2. An external degreasing and rinsing A hot phosphating operation A powdering through application of a polyester resin with an electrostatic spray gun (minimum thickness 40 to 50 microns) Final color green gray RAL 7033

The main characteristics of the coating guarantee: A gloss of 30 to 60 % for an angle of 60 (measured according to ASTM-D523)

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A salt spray resistance of 1000 hours (measured according to ASTMB117) A UV resistance without losses more than 10% gloss according to the RAL scale 1 (measured according to NFT 30-057, over a 3 months period). An adherence of between 0 and 1 (measured according to ASTMD3359)

L.

Accessories and standard equipment 1. The transformers shall be equipped with: 4 bi-directional flat rollers 2 lifting and untanking lugs 2 earthling terminals 1 filling plug 1 draining device 1 rating plate 1 "Danger Electricity" warning label 1 routine tests certificate 1 instruction manual for installation, commissioning and maintenance in English.

2.

Protection The transformers shall be equipped with a DGPT2 protection relay including: a. 1 gas detector/flow level indicator with one contact (for gas discharge and drop in liquid level) b. 1 over pressure contact (for internal pressure increase) c. 2 thermostats for alarm and tripping (for internal temperature increase) d. 1 dial type thermometer without contact.

2.6

LV COMPARTMENT A. B. LV Compartment shall comply with IEC 60439-1 recommendations.. The LV compartment shall be located on the opposite side of the MV compartment and is totally segregated from the transformer compartment. The accessible shall be through a double, gasketted, lockable door. All components shall be erected on a painted chassis, 5mm angular, fixed onto the skid of the kiosk.

C. D.

2.7

MISCELLANEOUS A. Internal lighting controlled by door operated switch shall be provided in HV and LV section. Socket outlet, 2P+E shall be provided in the LV compartment.

B.

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C.

MCB's or Fuse-carrier with fuses links for protection of socket & lighting shall be provided. All MV and LV cables shall be handled through the bottom. Labeling shall be white on black background, in English language. Texts should be approved.

D. E.

2.8

ROUTINE TESTS AND TYPE TESTS A. Routine Tests 1. The substation shall be tested in the factory according to applicable IEC standards against the following routine tests, and official test certificate shall be produced for each one: 2. Mechanical operation tests and checking the interlocking. Power-frequency withstands voltage test for 1minute. Check MV and LV wiring. LV equipment operation test. Usual visual examination.

The following tests shall be carried out on all the transformers after the manufacturing, enabling an official test certificate to be produced for each one: Measurement of windings resistance. Measurement of the transformation ratio and vector group Measurement of impedance voltage and load loss Measurement of no load loss and no load current Applied voltage dielectric test Induced voltage dielectric test

(All these tests shall be in accordance with IEC 60076-1 to 60076-5 standards). B. Type Tests Special Tests The following tests may be requested by the Engineer: 1. 2. 3. 4. 5. Temperature rise test. Lightning impulse test. Short circuit test. Noise level measurements in accordance with IEC 60551. Measurement of partial discharges.

(All these tests shall be in accordance with IEC 60076-1 to 60076-5 standards). The manufacturer shall produce a test report from an official laboratory on a transformer of the same design as those produced.

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PART 3 - EXECUTION 3.1 WORKMANSHIP A. Materials, products and equipment furnished by the contractor, shall be installed and all work shall be performed in a first-class workmanship manner, in conformity with the best trade practices and the printed directions of the applicable manufacturers; by skilled workers equipped to produce satisfactory results; in a safe, substantial manner so as to avoid undue stresses, rigid enough to prevent undue movement, so as to present a neat, orderly appearance and to facilitate operating, servicing, maintenance and repairing.

3.2

FOUNDATIONS AND SUPPORTS A. The contractor shall provide concrete pedestals, anchor bolts, hangers, channels, saddles, etc., for installation of equipment and apparatus shown on the drawings and specified in the various sections.

3.3

EQUIPMENT ERECTION A. All electrical equipment shall be installed in accordance with the manufacturer's recommendations, good electrical engineering practice, and the relevant drawings and specifications. All metal surfaces to be bolted shall be thoroughly cleaned before assembly. The connections shall be tightened with manual torque wrenches to the manufacturer's erection instructions. Ground equipment according to Section 16452 GROUNDING.

B.

3.4

EQUIPMENT TESTING AND COMMISSIONING A. After the installation is complete and properly adjusted, the contractor shall conduct operating tests. The various equipment and systems shall be demonstrated to operate in accordance with the requirements of the contract documents. Tests shall be performed in the presence of the Engineer. The contractor shall provide electric power, instruments and personnel necessary for performing the various tests. The testing of all electrical equipment shall include, but not be limited to, the items below. This shall be in addition to testing specified elsewhere in this specification. 1. 2. 3. General equipment check. Field wiring and ground system verification. Equipment adjustment.

B.

END OF SECTION

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