AAC SPECIFICATION

OIL FILLED DISTRIBUTION TRANSFORMERS

514/3 ISSUE 1 Copyright

CONTENTS PAGE

CONTENTS PAGE............................................................................................................................................1

1.0 SCOPE...............................................................................................................................................................3

2.0 TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER........................................3

3.0 DEFINITIONS..................................................................................................................................................3

4.0 REQUIREMENTS............................................................................................................................................4
4.1 INFORMATION TO BE SUBMITTED WITH TENDER ..................................................................................................4
4.2 INFORMATION TO BE SUBMITTED ON CONTRACT AWARD.......................................................................................4
4.3 SIZES........................................................................................................................................................4
4.4 CLIMATIC CONDITIONS..................................................................................................................................4
4.5 CONSTRUCTION...........................................................................................................................................5
4.6 OIL FILLING AND DESPATCHING......................................................................................................................5
4.7 FREE BREATHING TRANSFORMERS ...................................................................................................................5
4.8 SEALED TRANSFORMERS ................................................................................................................................5
4.9 CONSERVATORS..........................................................................................................................................5
4.10 OIL LEVEL INDICATOR................................................................................................................................6
4.11 THERMOMETERS ........................................................................................................................................6
4.12 OFF-CIRCUIT TAPPING SWITCH......................................................................................................................6
4.13 UNDERBASES ............................................................................................................................................6
4.14 LIFTING LUGS...........................................................................................................................................6
4.15 MECHANICAL ARRANGEMENT OF COMPONENTS................................................................................................6
4.16 GASKETS.................................................................................................................................................6
4.17 CABLE BOXES...........................................................................................................................................6
4.18 EARTHING................................................................................................................................................9
4.19 DISCONNECTING CHAMBERS ......................................................................................................................10
4.20 PRESSURE RELIEF....................................................................................................................................10
4.21 CORROSION PROTECTION..........................................................................................................................10
4.22 LOSSES.................................................................................................................................................11
4.23 IMPEDANCE VOLTAGE..............................................................................................................................11
4.24 WINDINGS.............................................................................................................................................11
5.0 QUALITY ASSURANCE PROVISIONS.....................................................................................................11
5.1 QUALITY MANAGEMENT..............................................................................................................................11
6.0 TEST AND INSPECTIONS...........................................................................................................................11
6.1 PROOF TESTS...........................................................................................................................................11
6.2 TYPE TESTS.............................................................................................................................................11
6.3 SPECIAL TESTS.........................................................................................................................................11
7.0 MARKING AND PACKING.........................................................................................................................12
7.1 MARKING................................................................................................................................................12
7.2 PACKING.................................................................................................................................................12
APPENDIX A : RELATED DOCUMENTS....................................................................................................13

APPENDIX B : RECORD OF AMENDMENTS............................................................................................13

APPENDIX C : INFORMATION BY THE ENGINEER..............................................................................14

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APPENDIX D : INFORMATION TO BE SUBMITTED WITH TRANSFORMER TENDERS.............18

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1.0 SCOPE

This specification details the manufacture, factory testing and delivery of 3 phase 50 Hz double
wound, oil immersed, natural air cooled (ONAN) outdoor power transformers.

Where applicable the transformers shall comply with the requirements of SABS 780 and shall
bear the SABS mark.

2.0 TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER

2.1 The title, date, reference number and issue of this specification.

2.2 Transformer Data sheet (see Appendix C).

3.0 DEFINITIONS

For the purpose of this specification, the following definitions shall apply.

APPROVED/ACCEPTABLE : Approved by and acceptable to the Engineer in writing

BS : British Standard

SABS : South African Bureau of Standards

QAP : An AA Company Quality Assurance Procedure

QUALITY PLAN : A document compiled by the Contractor detailing all

major events in the products (or service) including but
not necessarily limited to inspection requirements, test
procedures and acceptance/rejection criteria, sampling
plans and equipment to be employed for Quality
Control purposes during manufacture and prior to the
despatch. Full details of sub-contractor controls shall
be included

QUALITY ASSURANCE : A Quality Surveillance Authority appointed by the

REPRESENTATIVE (QAR) Contractor and approved by the Engineer

The following terms are defined in the General Conditions of Contract:

AA Company, Company, Contractor, Engineer.

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4.0 REQUIREMENTS

4.1 Information to be submitted with tender

Impedance voltage.

Guaranteed no load and load losses.

Outline sketch.

A fully completed copy of Appendix D : "Information to be supplied with transformer tenders".

4.2 Information to be submitted on contract award

Certified drawings of the transformer(s) showing arrangement and details.

Note: These drawings shall be approved before manufacturing commences.

A drawing of the rating plate.

Four copies of test certificates covering all tests performed

4.3 Sizes

4.3.1 Rated output

10, 25, 50, 100, 200, 315, 400, 500, 630, 800, 1000, 1250, 1600 or 2000 kVA. The selected
KVA shall be shown on the attached Data Sheet.

4.3.2 Normal voltage ratio

The no load voltage ratio shall be shown on the Data Sheet and selected from one of the
following: -

11000/550-317
11000/400-231
6600/550-317
6600/400-231
3300/550-317
525/400-231

4.4 Climatic conditions

Transformers shall be suitable for surface and underground use and climatic conditions as
specified in SABS 780, viz:

Altitude not exceeding 1800m.

Maximum ambient air temperature 40°C.

Daily average ambient air temperature not exceeding 30°C.

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4.5 Construction

Transformers shall be of robust construction and tank welds on transformers of 1000 KVA and
larger shall be inspected by the QAR if called for on the Data Sheet. The costs of independent
testing shall be borne by the Company.

The Contractor shall make the tanks available at his works for test and shall not proceed with
assembly until the tanks have been inspected by the QAR. Any work that is found
unacceptable shall be repaired or made good by the Contractor at no extra cost to the
Company.

Cooling fins on transformers shall be welded or bolted on. See Data Sheet, Appendix C.

4.6 Oil filling and despatching

4.6.1 Oil: shall comply with the requirements of SABS 555.

4.6.2 Transformers: shall be thoroughly dried out by the Contractor and filled with oil before
despatch.

4.7 Free breathing transformers

Each free breathing transformer shall be supplied complete with an oil sealed silica gel
breather, a drain valve at the lowest point of the tank, and an oil filling pipe.

4.8 Sealed transformers

Sealed transformers shall comply with "Category 1 Sealed Transformer" as stipulated in

subsection 2.1 of SABS 780, viz. "A sealed transformer in which the total volume of oil, gas,
air or any combination of these remains constant over the temperature range".

Sealed type transformers, if called for on the Data Sheet, may be used up to and including 630
kVA rating.

All sealed transformers shall have bolt on lids.

4.9 Conservators

4.9.1 Free breathing transformers 630 kVA and above: shall be fitted with bolt on conservators.

4.9.2 Transformers 1000 kVA and above: shall be fitted with gas-and-oil actuated relays
(Buchholz or approved equivalent).

4.9.3 Transformers less than 1000 KVA: shall be fitted with gas and oil actuated relays only when
indicated on the Data Sheet.

4.9.4 A drain valve: shall be fitted to the lowest point of the conservator tank. The pipe connecting
the conservator tanks to the transformer tank shall protrude at least 50 mm above the lowest
point of the conservator and enter the transformer tank in such a position that no sediment can
fall onto the core or windings.

4.9.5 Conservators: shall be removable for transport in confined spaces.

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4.10 Oil level indicator

Oil level indicators shall be provided on all transformers with maximum and minimum markings
for hot and cold oil.

4.11 Thermometers

All transformers above 100 kVA shall have top oil thermometer pockets. Dial type
thermometers shall only be provided when called for on the Data Sheet. These thermometers
shall comply with Subsection 3.14 of SABS 780-1979, viz.

Graduated in degrees Centigrade

Diameter approximately 102 mm
Re-settable maximum temperature indicator, and include:

a pair of adjustable, normally open alarm contacts, and

a pair of adjustable, normally open contacts for tripping purposes.

4.12 Off-circuit tapping switch

An off-circuit Merlin Gerin three gang 15 kV 125 Amp Industralec code 4000 series tap switch
or approved equivalent shall be fitted in accordance with the requirements of SABS 780.

The switch shall be in a straight line to the operating wheel outside the tank and shall be in
alignment.

The tap position indication shall be such that when positioned on a number the tap switch is in
its correct operating position. The handle shall be padlockable in any tap position and shall
have end stops at the two extreme tap positions.

4.13 Underbases

Longitudinal skid underbases with hauling eyes shall be provided on all transformers. Wheels
and axles shall not be fitted.

4.14 Lifting lugs

Bolted-on lifting lugs with a factor of safety of 10 shall be provided on all transformers.

4.15 Mechanical arrangement of components

The transformer shall be of a robust construction and the core strongly secured. The
arrangement of the various components shall be such that transit damage will be prevented.

4.16 Gaskets

All gaskets shall be of the interlocking pattern and shall be of permanently oil-resisting
material.

4.17 Cable boxes

4.17.1 General

Cable sealing boxes shall comply with the requirements of BS 2562.

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4.17.1.1 All cable boxes: shall be welded to the tank. Alternatively they shall be bolted on in such a
manner that the box can be removed without draining the transformer oil (see the Data Sheet).

If bolted on it shall be possible to alter the position of the box to suit bottom, top or side cable
entry. Transformers shall be despatched with cable boxes in the bottom entry position.

4.17.1.2 Cable boxes shall be suitably sized: to provide the clearances between terminals and
insulator lengths inside cable boxes for air insulation as given in the Tables 1 and 2 below.

4.17.1.3 The cable boxes shall be weatherproof: to IP 55, and shall have a ventilation gauze
covered aperture of approximately 15 mm diameter.

4.17.1.4 Cable boxes shall be fitted: with removable gland plates drilled for Pratley or approved
equivalent mechanical glands, or fitted with the Rand Mines Glands for the cables specified in
the Data Sheet. Rand Mines Glands where fitted for 3 core HT cable shall be suitable for any
cable size from 35 mm² to 185 mm² cross sectional area 3 core cable.

For single core cables the gland plate shall be of non magnetic material.

For single core lead covered cable the cable glands shall be insulated from the gland plate.

The cable gland plate shall not be less than 900mm above the base of the transformer.

4.17.2 H T cable boxes

4.17.2.1 Three separate phase connection bushings: shall be brought out into the cable box.

4.17.2.2 An earthing tud: welded to the main tank, suitable for an earthing lug of the same size as the
main phase conductors, shall be provided inside the cable box.

4.17.2.3 The preferred clearances: and minimum acceptable clearances in the cable boxes shall be
as in Table 1.

4.17.3 L.T. cable boxes

4.17.3.1 For 550 Volt cable box: for primary or secondary windings, three separate phase connection
bushing shall be brought out inside the cable box. The neutral star point connection of the
secondary winding shall be brought out into a separate box as described in Clause 4.18.1.

4.17.3.2 For 400 Volt cable box: three phase bushings and neutral star point, bushing shall be brought
out inside the cable box.

A second neutral star point bushing shall be brought out in a separate box (see Clause
4.18.2).

4.17.3.3 The preferred clearance: and minimum acceptable clearance in the cable box shall be as in
Table 2.

4.17.4 Bushings

All bushings shall be threaded or have drilled flags suitable for lug terminations and shall
comply with the requirements of SABS 833.

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TABLE 1

H.T. CABLE BOX CLEARANCES

1 2 3 4 5 6 7
PREFERRED CLEARANCE MINIMUM ACCEPTABLE
CLEARANCE
mm mm
11000V 6600V 3300V 11000V 6600V 3300V
Length of Insulator 127 127 90 90 90 50
Phase to Earth 77 77 65 65 65 50
Phase to Phase 127 127 90 90 90 50

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TABLE 2

L.T. CABLE BOX CLEARANCES

1 2 3
PREFERRED CLEARANCE MINIMUM ACCEPTABLE
CLEARANCE
mm mm
550V and 400V 550V and 400V
Length of Insulator 25 19
Phase to Earth 25 19
Star Point to Earth 25 19
Phase to Phase 25 19
Phase to Star Point 25 19

4.18 Earthing

4.18.1 Transformers having 550 Volt Secondaries

To allow resistive earthing to the star point two adjoining enclosures shall be provided, one
housing the neutral (star point) bushing and current transformer and the second a neutral
earthing resistor.

4.18.1.1 Star Point Bushing Enclosure

This enclosure shall be weatherproof to IP55.

The clearance shall be as given in Table 2.

Where called for on the data sheet a current transformer ratio 100/1, Class 1, 10 VA ring type
protection current transformer (minimum aperture 30 mm) shall be installed. Where the
current transformer is not called for, space shall be allowed for mounting of the current
transformer at a future date.

A 16 mm² PVC insulated conductor shall connect the star point bushing to the earthing resistor
(see Clause 4.18.1.2) and pass twice through the current transformer. A suitable grommet
shall be provided in the side of the box for this conductor.

A removable gland tray shall be fitted drilled for a Pratley, or approved equivalent gland,
suitable for the cable size as given in the Data Sheet.

4.18.1.2 Neutral Earthing Resistor Enclosure

This enclosure shall be screened off to allow ventilation of the resistor.

The resistor shall be capable of carrying the maximum earth fault current continuously.

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The resistor shall comprise four 27 ohm resistance elements which may be connected, by
captive links, to provide a resistance bank of 27 ohms (which would restrict the earth fault
current to 10 amps) or 108 ohms (which would restrict the earth fault current to 2,5 amps).

One side of the resistor shall connect to the star point bushing (see Clause 4.18.1.1 and the
other to the system earth mat. A suitable opening shall be allowed into the enclosure for the
connection to the earth mat.

To allow the integrity of the resistor to be monitored the two ends of the resistance bank shall
be wired to terminals and a drilled cable gland provided, if called for in the data sheet.

4.18.2 Transformers having 400 Volt Secondaries

The neutral (star point) shall be solidly earthed and the transformers shall be provided with a
neutral bushing inside the L.T. cable box and a second neutral bushing on the tank external to
the L.T. cable box.

The tank mounted bushing shall be solidly earthed to the earth mat.

Where called for on the Data Sheet a current transformer in a suitable enclosure shall be fitted
so that the conductor connecting the earth mat to the star point neutral bushing passes
through the C T.

The current transformer shall be 100/1 amp ratio, Class 1, 10 VA ring type protection C T.

The current transformer enclosure shall be fitted with a removable gland tray drilled for a
Pratley or approved equivalent gland suitable for the cable size as given in the Data Sheet.

4.19 Disconnecting Chambers

No disconnecting chambers between the cable terminations and transformer bushings is

required.

4.20 Pressure Relief

Transformers of size 800 KVA and above shall be fitted with pressure relief valves. The
design of the system shall be such that the pressure build up inside the tank due to faults will
cause the pressure relief system to operate before any distortion or fracture of the tank occurs.

4.21 Corrosion Protection

Corrosion protection shall comply with the requirements of AA Company 164050 and CPS122.

Colour of the final coat shall be Avocado Green.

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4.22 Losses

Transformers shall be of the low loss type and losses shall comply with the requirements of
Table 6 of SABS 780-1979 with the exception that Section 4.9 (a) shall not apply.

4.23 Impedance Voltage

Impedance voltage shall comply with the requirements of Section 4.8 of SABS 780-1979.

Should a transformer be required to operate in parallel with an existing transformer, full details
shall be supplied in the Data Sheet.

4.24 Windings

The windings shall be spiral, disc or foil type primary and secondary. The internal winding
connections shall be Dyn 11.

5.0 QUALITY ASSURANCE PROVISIONS

5.1 Quality management

The requirement of SABS ISO 9001 shall apply. All volitional requirements in SABS ISO 9001
shall be mandatory requirements for material supplied against this specification.

6.0 TEST AND INSPECTIONS

All testing shall be in accordance with the requirements of SABS 780-1979.

When type tests and special tests are required, they shall be indicated on the Data Sheet.

6.1 Proof Tests

Measurement of winding resistance.

Measurement of voltage ratio and verification of polarity and connection symbol.
Measurement of impedance voltage and load loss.
Measurement of no-load volts and no-load current.
Induced overvoltage withstand test.
Separate source voltage withstand test.
Measurement of paint thickness.
Test for effectiveness of sealing.

6.2 Type Tests

Full impulse voltage withstand test.

Full and chopped impulse voltage withstand test.
Temperature rise test.
Tank stiffness test.

6.3 Special Tests

Short-circuit withstand test.

Measurement of audio-sound level.

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7.0 MARKING AND PACKING

7.1 Marking

A plate shall be securely attached to the transformer and shall contain, but shall not
necessarily be limited to, the following information:

Primary voltage and full load current

Secondary voltage and full load current
Rating % impedance
Vector group
Frequency
Maximum temperature
Oil capacity

A schematic diagram showing the primary and secondary windings and top positions with their
tabulated values shall be marked on a separate plate and securely attached to the
transformer.

7.2 Packing

The transformer shall be suitably packed to provide protection from physical damage and
adverse climatic conditions during transportation.

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APPENDIX A : RELATED DOCUMENTS

AAC 164/50 : Corrosion protection of steelwork with coatings

CPS 122 : High build micaceous iron oxide epoxy and polyurethane system

BS 2562 : Specification for cable boxes for transformers and reactors

SABS ISO 9001 : Quality Management Systems

SABS 555 : Mineral insulating oil for transformers and switchgear

SABS 780 : Distribution transformers

SABS 833 : High and low voltage bushings

APPENDIX B : RECORD OF AMENDMENTS

Issue 1 : Clause 4.17.1.4 amended (for 900mm)

Clause 4.17.1.1 amended (for welded boxes)
App. C amended (26) for boxes
(A.B. Johnston 1994-02-17)

Editorial version: 23 January 2004.

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APPENDIX C : INFORMATION BY THE ENGINEER

Note: Indicate with "X" applicable choice.

1. Number of Transformers

2. Power Rating ………….. 10 25 50 100 200 315 400

500 630 800 1000 1250 1600 2000 KVA

3. Phases ………………………………………………………………………………………..…….3

4. Primary Voltages …………. 525 3300 6600 11000 Volts

5. Secondary Voltages 550/317 400/231 Volts

6.1 Back-up Earth Fault CT required (see Clauses YES NO

4.18.1 and 4.18.2)

6.2 Neutral Earthing Resistor Required YES NO

7. Frequency …………………………………………………………………………………………..50 Hz

8. Vector Group ………………………………………………………………………………………..Dyn 11

9. Systems

a) Primary Above 1 kV:500 MVA at 11 kV

350 MVA at 6,6 kV/150 MVA at 3,3 kV
Neutral Earthing Compensator Earthed
Limiting earth fault currents to ± 355 amps

Below 1 Kv:16 MVA at 525 Volt.

b) Secondary : See Clause 4.18 of specification

10 Tapping Switch …………………………………………………………………………………Off

circuit

11 Tappings ………………………………………………………………..95 97,5 100 102,5 105%

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APPENDIX C : INFORMATION BY THE ENGINEER (Continued)

12 Losses .................................…………………………………………............ Low - Loss type

13 Cooling .......………………………………………........................................ ONAN

14 Thermometer pockets …………………………................ Standard for 100 KVA and above

15 Dial Type Thermometer ........................ YES NO

16 Conservator ...…………………………………................. Standard from 630 KVA and above

17 a) Free breathing transformer YES NO

b) Sealed transformer YES NO

18 Gas-and-oil Actuated Relay…………………………….. YES NO

(Standard for transformers 1000 KVA and above)

19 Cable Connections to be provided for:

Type Number of Size mm2 Cores

of Cable Cables

Primary

Secondary

Back-up E/F CT

NER Monitor

20. DIMENSIONAL LIMITS (If necessary) ……………………………………………………….

21 Is transformer required to operate in parallel with YES NO

an existing transformers?

If YES, provide the following information of the existing transformer:

APPENDIX C : INFORMATION BY THE ENGINEER (Continued)

Rating …………...................... KVA

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Vector Group ………………................

Turns ratio at rated voltage …………........................

Turns ratio corresponding to tappings …………........................

Tappings on primary or secondary side Primary/Secondary

Load loss at rated current (corrected to 75°C) ………………….............. Watt

Impedance voltage related to principle tapping ………….........................

Vector Group ……………......................

22 Tank Welding Inspection Required YES NO

23 Tests ...…………………………………………........... Proof Test/Type Test/Special Test*

(Note: Proof tests will normally be sufficient)

*Delete parts not applicable.

24 Colour: SABS 1091 - 1975 Avocado Code C26.

25 Cooling fins to be colted on YES NO

26 Cable boxes to be bolted on YES NO

27. Additional Quality Assurance requirements.

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APPENDIX C : INFORMATION BY THE ENGINEER (Continued)

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28. Additional Information

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APPENDIX D : INFORMATION TO BE SUBMITTED WITH TRANSFORMER TENDERS

ENQUIRY NUMBER: TENDERER:DATE:

1. TRANSFORMER SIZE (KVA)

2. Rated KVA at maximum daily average ambient…………………………....................

temperature of 40°C …………….....................

3. Number of phases .......................……………………………………….......................

4. Frequency ...........................………………..... Hz…………………….......................

5. Voltage ratio (no load)..............………………………………………….......................

6. Tappings ......................…………………………………………………….....................

7. Vector Group ................…………………………………………………….....................

8. No load loss ......................………………...... watts…………………….....................

9. Load Loss ...........................……………….... watts…………………….....................

10. Total loss at rated current ..……………......... watts…………………........................

11. Regulation at 1,0 p.f. and rated current………………………………….......................

12. Regulation at 0,8 p.f. and rated current………………………………….......................

13. Regulation at 0,4 p.f. and rated current………………………………….......................

14. Impedance voltage at rated current .....……… %……………………….....................

15. Reactance voltage at rated current ……..………... %……………………….....................

16. Temperature rise at rated KVA by thermometer

in oil .........................…………………….......... °C…………………….......................

17. Temperature rise at rated KVA by resistance

of windings............................…………………. °C…………………….......................

18. Mass of transformer core and windings ..…….. kg……………………......................

19. Mass of tank and fittings .............……………... kg……………………......................

20. Mass of oil .........................…………………..... kg……………………......................

21. Total mass ........................…………………...... kg……………………......................

22. Volume of oil ........................………………….. ( )……………………......................

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APPENDIX D : INFORMATION TO BE SUBMITTED WITH TRANSFORMER TENDERS

(Continued)

23. Overall dimensions

23.1 Length …………… . (mm) ................…………………………..

23.2 Width .......................... (mm) …………………………..................

23.3 Height ..................... (mm) …………………………..................

24. Material used for winding conductors ....………………………....................

25. Current density of windings at rated current

25.1 Primary winding ................. (A/mm²)………………...................

25.2 Secondary winding ............... (A/mm²)……………….. .................

26. Flux density of core ...............……….. (Wb/m²)…………………................

27. External area of cooling radiators ..… (m²)……………………….................

28. Maximum sound power level measured 1 metre

from transformer (at rated load) ....…..(dB)……………………....................

29. Insulation class

29.1 H.T. windings .................………………………………....................

29.2 L.T. windings ................…………………………………..................

30. Cable box dimensions (mm)

30.1 H.T. cable box .....………. High ……........... Wide …............ Deep

30.2 L.T. cable box .....………. High ……........... Wide …............ Deep

30.3 Earthing resistor fitted ............………………………............ Yes/No

30.4 Back up E/F CT fitted .............………………………............ Yes/No

31. Impulse withstand ...................…... (Kv)…………………………...................

32. Extent to which SABS 0157 (Quality Assurance)

is implemented ......................……………………………………....................

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APPENDIX D : INFORMATION TO BE SUBMITTED WITH TRANSFORMER TENDERS

(Continued)

The following are the only deviations from specification:

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COMPLETED BY: NAME: DESIGNATION:________

SIGNATURE: DATE: TEL. NO:_____________

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