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Specification for Impulse Voltage Generator (3200kV Impulse Voltage Generator for Large Power Transformers) And (1200kV Impulse Voltage Generator for Medium Power Transformers) Compiled by: Rodger Moore Rotek and Roshcon T&SS Engineering Department Date 2014-12-13 Number of pages 7 1 CONTENTS 1. Background 3 2. Objective 3 3. Test bay upgrade requirements of equipment 3 3.1 Engineering Philosophy 3 3.2 Maintenance Philosophy 3 3.3 Operating Philosophy 3 3.4 Project Management Philosophy 3 4. Scope 4 4.1 Minimum requirements 4 4.2 Main Components 5 4.3 Power supply requirement 5 5. Standards, Codes and Specifications 5 6. Guarantees 6 7. Testing and Inspection 6 8. Quality Management 6 9. Safety Management 6 10. Environmental Management 7 2 1. Background Rotek Engineering’s Transformer and Switchgear Services Division is an organisation specialising in the repairs of transformers. Its workshop is situated in Johannesburg, South Africa at an altitude of 1800 metres above sea level. It is equipped to manufacture replacement windings for three phase transformers up to 800 MVA with voltages ranging up to 765 kV. The type of repairs carried out on the transformers necessitates HV electrical testing to prove the repairs and serviceability of the units. At present Rotek is able to carry out routine and temperature rise tests on Power and furnace transformers as required by IEC 60076, part 1, 2 and 3 but requires to upgrade the Impulse Voltage Generators and new 132kV bushing test facility. Provision of the required power supply, including power cable and switchgear, must be included in the tender. 2. Objective Procure the necessary equipment to facilitate Impulse tests on medium and large power transformers up to 800 MVA and voltages ranging up to 400 kV and 765 kV. Impulse Voltage test is described in IEC 60076 part 3 documentation. 3. Test Bay Impulse Voltage Generator upgrade requirements 3.1 Engineering Philosophy The various equipment and associated auxiliaries should be designed in accordance with internationally accepted standards. 3.2 Maintenance Philosophy Maintenance of the equipment and associated auxiliaries should be kept at a minimum. 3.3 Operating Philosophy The equipment and associated auxiliaries should be designed in such a manner as to cost effectively improve safety, reliability and production. 3.4 Project Management Philosophy The project must be tendered on the bases of a “Turnkey” project. It is required that the supplier/contractor takes total responsibility the civil design, electrical design, manufacture, test, deliver, erection/installation, commissioning and civil works of the transformer under test and is covered by Professional and Contractors Liability Insurance. 3 4. Scope 4.1 Minimum requirements The scope of work includes the following: Trenching, Installation and commissioning of the required supply cable (400V) to the to the impulse voltage generator. Design, manufacture, test, deliver, erection/installation, commissioning and demonstration of all equipment to facilitate impulse voltage testing of medium and large power transformers. Installation of all required protection systems. Contractor must indicate the required area needed for installation (an outline drawing of the current layout of the workshop will be provided on request). Contractor supervision during installation. Indication must be stated regarding the delivery and installation time of equipment. Operating and maintenance manuals to be supplied with all equipment. OEM / Contractor to provide training of Rotek test staff to conduct impulse voltage testing, use of Glaninger circuit and overshoot compensating capacitor. Training must be carried out on a transformer to simulate a real experience (Transformer will be supplied by Rotek). Equipment insulation must be suitable rated for operation at 1800m above sea level. Adequate kilo-joule (kJ) rating to test to IEC 60076 part 3 Specification PLC based control Technique, with simple and reliable structure. Fiber-optic control system, ensuring safety at high voltages. Stage capacitor grounding circuit, ensuring safety to personnel when altering internal resistors. Protective grounding device operating automatically at power outages. Reliable and accurate triggering system. Series resistors must be interchangeable with one another as well as parallel resistors. Short reconfiguration times (internal ladder, internal platforms, handy plugin resistors and connections, special resistor support compartments on every stage). Expandable Stage capacity. An overshoot compensating capacitor to test very high capacitive loads still according to standard IEC impulse specifications. Glaninger circuit to test very low inductive loads. Equipment must be able to test power transformers with lightning and switching impulses. Front, tail and termination resistors according to IEC 60076-3 for switching impulse 4 4.2 Main components 4.3 3200kV impulse voltage generator with air cushion. Charging unit Impulse voltage divider Chopping gap Computer measuring and fiber-optic control system with operating desk Load capacitor for wave shape correction with switching impulses Shunts for current measurement Front, tail and termination resistors for wave shape correction with switching impulses Power Supply Requirement Tender to specify the specific power supply requirements for: Impulse voltage generator for large power transformers Impulse voltage generator for medium power transformers 5. Standards, Codes and Specifications Whenever reference is made to a code or standard, it shall be understood that the latest edition as of the date of contract award shall govern. In the event of conflicts between this specification and other documents, the most stringent code or standard shall apply. The following standards and specifications shall apply; IEC 60060-1, High-voltage test techniques – Part 1: General definitions and test requirements IEC 60060-2, High-voltage test techniques – Part 2: Measuring systems IEC 60076-1,Power transformers – Part 1: General IEC 60076-3, Power transformers – Part 3: Insulation levels, dielectric tests and external IEC 61083-1, Instruments and software used for measurement in highvoltage impulse tests – Part 1: Requirements for instruments IEC 61083-2, Digital recorders for measurements in high-voltage impulse tests – Part 2: Evaluation of software used for the determination of the parameters of impulse waveforms 5 6. Guarantees The equipment supplied is guaranteed against faulty material or workmanship for a period of 12 months after handing-over of the equipment. The performance of equipment supplied including capacity, charge/discharge conditions, efficiency and outputs meet design intent. 7. Testing and Inspection The manufacturer shall submit an Inspection and Test Plan which shall be reviewed and approved by Rotek prior to start of fabrication. Test and inspection of the equipment is required at the manufacturer’s premises to ensure the equipment supplied will meet its design intent. 8. Quality Management Quality management The Contractor defines the level of QA/QC or inspection imposed on his SubContractors and suppliers. The test equipment is manufactured in accordance with a quality assurance management system complying with ISO 9001:2000 and approved by the Employer. The Employer reserves the right to conduct surveillance and periodic inspections at the Contractor’s Works during the manufacturing phase. The programming of inspections, hold and witness points needs to be incorporated in the Quality plans and is agreed between the Employer and the Contractor prior to undertaking any work. 9. Safety Management Safety Management The health and safety requirements are as per Rotek Standard EQH-I011 HEALT AND SAFETY SPECIFICTION FOR CONTRACTORS. The Contractor takes every precaution to ensure safety and to protect the Works and temporary works. The Contractor is responsible for the safety and security of his personnel, materials on site and the Works at all times. Any electrical equipment, or appliances, used by the Contractor conforms to the applicable OHS ACT safety standards and is maintained in a safe and proper working condition. 6 The Contractor adheres to the safety regulations pertaining to the Rotek workshops in addition to all requirements of the Occupational, Health and Safety Act of 1993 and all later revisions thereof. The Contractor provides all the required safety and personal protective equipment to his staff for the duration of the contract. Safety barriers and access scaffolding is temporary works and are the responsibility of the Contractor. The Contractor complies with the requirements of the Construction Regulation, 2003 No. R1010 of the Act, and forwards proof of Notification of Construction Works to the Department of Labour as required in the Construction regulations. The Contractor and his personnel attend an induction meeting on site and sign the attendance sheet provided as proof of attendance . 10. Environmental Management Environmental Management All environmental requirements shall be adhered to as per ISO 14001:2004. The Contractor acquaints himself with all statutory and local environment regulations and adheres to these without exception. The Contractor complies with the Hazardous Chemical Regulations when using any hazardous chemicals, as well as complying with the requirements of the National Environmental Management Act of 1988. 7