Federal-Pacific Unit Substation Transformers

Federal-Pacific Unit Substation Transformers
Unit Substation Transformers
5 and 15 kV Class
DOE 2010 Efficiency Compliant
Unit Substation
ISO 9001:2008
REGISTERED
83
General Information
Description
Federal Pacific unit substation transformers are available in a wide variety
of types and ratings to provide reliable
and versatile electrical distribution.
Medium voltage dry-type transformers
must comply with the new Department of
Energy efficiency regulations published
in Table 1.2 of the Federal Register/Vol.
72, No. 197 / Friday, October 12, 2007.
This is the DOE 10 CFR 431 Section 196.
Unit Substation
The changing needs and variable load
densities of industrial and commercial power systems create the need to
locate transformers close to the electrical center of the load — providing
flexibility for change and economical
distribution of power.
Federal Pacific dry-type transformers
are ideally suited for these applications. The ventilated air-cooled construction eliminates the concern for
contamination and toxicity of cooling
liquids. They do not require the expensive vaults, fluid leakage containment
provisions, or fire protection systems
needed for liquid filled units to satisfy
National Electric Code requirements.
Industry Standards
Federal Pacific Unit Substation Transformers are designed and tested in accordance with the following standards:
• IEEE C57.12.01 General Requirements
for Distribution, Power and Regulating
Transformers.
• IEEE C57.12.91 Standard Test Code for
Dry-Type Distribution and Power Transformers.
• NEMA 210 Secondary Unit Substations.
• NEMA ST-20 Dry-Type Transformers
for General Applications.
• NEMA TR-27 Commercial, Institutional
and Industrial Dry-Type Transformers.
• IEEE 693-2005 Seismic
Tested Performance
A high level of transformer reliability
for trouble-free installation and operation, all transformers manufactured by
Federal Pacific are tested in accordance
with NEMA and IEEE Standards:
Ratio Test is performed on rated voltage connection and tap connections to
assure proper turns ratio on all connections.
Lower installed costs and minimum
maintenance requirements make
Federal Pacific Dry-Type Substation
Transformers an ideal choice for new
or existing installations.
Polarity Test and phase relation tests
are made to ensure proper polarity and
marking because of their importance
in paralleling or banking two or more
transformers.
Transformers are available in three
phase ratings from 112-1/2 KVA to
10000 KVA. All standard primary and
secondary voltage ratings are provided
to match load requirements to the distribution system.
No-load (excitation) Loss Test determines the losses of a transformer
which is excited at rated voltage and
frequency, but which is not supplying
a load. Transformer excitation loss
consists mainly of the iron loss in the
transformer core.
Units can be arranged for standard
direct connection to high voltage and
low voltage distribution protective
equipment or provided as individual
transformers.
84
Load Loss Test determines the amount
of losses in the transformer when carrying full rated load. These losses
consist primarily of I2R losses in the
primary and secondary winding and
ensure that specifications of the transformer design are met.
Excitation Current Test determines
the current necessary to maintain transformer excitation.
Resistance Test is performed on the
transformer windings and is used to
determine I 2 R loss.
Impedance Test is made to insure that
transformer design standards are attained.
Dielectric Test (applied and induced
potential) checks the insulation and
workmanship to demonstrate that the
transformer has been designed and
manufactured to meet the insulation
tests required by the standards.
Applied Potential Tests are made by
impressing between windings and between each winding and ground, a low
frequency voltage in accordance with
the following:
Rated Voltage of
Winding, Volts
250
600
2500
5000
8700
15000
Test Potential,
RMS kV
4.0
4.0
10.0
12.0
19.0
34.0
Induced Potential Tests call for overexciting the transformer by applying
between the terminals on one winding
a voltage of twice the normal voltage
developed in the winding for a period
of 7200 cycles. Partial Discharge (PD)
is performed during the induced potential test.
Unit Substation Arrangements
Arrangements
Incoming Line Air
Interrupter Switch
The Type Auto-jet II® air interrupter
switch, two position (open-close),
three pole with manually operated,
stored-energy mechanism provides
quick-make, quick-break operation for
disconnecting the transformer incoming line. Utilized with power or current
limiting fuses, the switch provides
safe, fast, and reliable protection for
NEMA 3-R
The 1200A switch is available with
61,000 amp asymmetrical rating (optional).
The switch compartment is bolted
directly to the high voltage side of the
transformer section. Cable entrance
can be at top or bottom for either single or loop feed. Fuses, when specified,
are located in a compartment under
the interrupter switch. A hinged door
allows access to fuses and is provided
with a mechanical interlock to prevent
the door opening unless the switch is
in the "open" position. Standard fuses,
when supplied, are the current limiting,
non-disconnect type. Lightning arresters and key interlocks are optionally
available.
Incoming Line Terminal
Compartment
When a disconnect or overcurrent
device is not required as an integral
part of the lineup, an air-filled terminal
compartment (ATC) is bolted directly
to the high voltage end of the transformer section. The metal-enclosed
ATC terminal compartment matches
the height and depth of the transformer
section and is provided with bolt-on
end panels for accessibility to terminal
connections. The compartment can be
arranged for single or loop feed with
potheads or clamp-type terminals for
either top or bottom cable entrance.
Lightning arresters can be supplied
when required for protection against
voltage surges.
Low Voltage Distribution
Sections
A complete selection of distribution
and protective equipment is available
to meet application requirements. Unit
substation transformers are arranged
for direct connection to a variety of
equipment including low voltage
drawout switchgear, distribution
switchboards, group mounted power
panelboards and motor control centers.
For those applications where secondary distribution equipment is not required, an outgoing air-filled terminal
compartment (ATC) can be provided
for top or bottom cable entrance. The
compartment bolts directly to the transformer and has removable end panels
for accessibility. Provisions can also be
made to accommodate busway.
Auto- jet II® Switch
85
Unit Substation
Federal Pacific unit substation transformers meet a wide variety of application requirements with the highest
degree of service reliability. Federal
Pacific substations are coordinated,
engineered electrical centers designed
to safely step down distribution voltage
to utilization voltage.It usually supplies secondary voltages ranging from
208Y/120 to 600 volts and primary
voltages of 2400 to 13800 volts. They
typically provide power to industrial
plants, office buildings, commercial
buildings, public buildings, hospitals
and schools. The form, rating, and
characteristics of unit substations and
their transformers are determined by
the design of the electrical distribution
system and the requirements of the
particular loads and installation conditions.
high voltage circuits. The Auto-jet II®
switch is rated 600 or 1200 amp continuous, 600 or 1200 amp load-break
with a high fault closing capacity of
40,000 amp asymmetrical.
Features of Typical 15 kV
Substation Transformer
1. Round cylindrical coils assure
proper ventilation and provide mechanical strength for fault stresses.
The units are either barrel wound
or disc wound (depending on voltage) using aluminum conductor
with insulated coil supports.
2. Core structures are fabricated in
a "stepped" configuration from
special high-grade, cold rolled,
silicon steel. The steel laminations
are clamped at the top and bottom
to absorb vertical stresses on the
core.
Unit Substation
3. 220°C insulation systems using
Nomex® paper and resin glass laminates provides long operating life
and quiet operation. The complete
core and coil assembly is impregnated with polyester varnish and
86
oven cured to make the assembly
highly resistant to moisture.
4. High dielectric interphase barriers
assure positive phase to phase insulating characteristics.
5. High voltage tap connections are
easily accessible by removal of
front panels. The centrally located
taps are changed by moving jumpers between connection points
when the transformer is de-energized.
6. Rugged enclosure base with provisions for lifting, jacking, towing,
skidding or rolling for installation.
7. Rigidly braced low voltage bus
bars arranged for proper electrical
connections to the transformer. The
low voltage bus is equipped with
flexible connectors to the core and
coil assembly to reduce transmission of vibration to the connected
equipment.
8. Diagrammatic nameplate provides
complete rating and connection
information.
9. Vibration isolation pads isolate
core and coil assembly from the
base structure to reduce sound
levels.
10.Optional fan cooling equipment
to provide an additional 33-1/3%
KVA capacity for units with selfcooled ratings of 300 KVA and
above. (Provisions for future
forced air cooling are provided as
standard — including sufficient
current-carrying capacity on internal bus bars.) Fans and controls
can be installed at the factory or
can be shipped for installation at
the jobsite.
Core and Coil Assembly
Core Construction
The transformer cores are made of high
grade silicon electrical steel laminations with high magnetic permeability.
Precision steel cutting machines are
used to cut the steel laminations with
precise squareness and miter and to be
free of burrs.
Laminations are hand stacked to computer generated specifications to assure
correct positioning for close fitting
joints to minimize noise and core loss.
Each lamination has an insulating coating bonded to both sides to minimize
eddy-current losses.
Coil Construction
Coils are precision wound in a circular
configuration using aluminum conductor material as standard. Copper
conductors can also be provided as an
option.
On low voltage where possible,
sheet-wound secondary windings are
used. The windings are separated by
insulation layers and spacers. These
sheet windings offer the advantage of
virtually eliminating axial short circuit
stresses.
Complete Core and Coil Assembly
Assembly
The completed coil units are placed
on the core legs. Top core yokes are
put into place and securely clamped.
Electrical connections are made using
welded aluminum or brazed copper, to
ensure reliable service.
Coils may be vacuum pressure impregnated, when specified. After installation of the mounting hardware, the
complete core and coil assembly is
submersed and impregnated with an insulating varnish. The assembly is completely coated to provide moisture and
dirt resistance as well as high dielectric
strength. After dipping, the varnish is
fully cured in a drying oven.
Completed core and coil assemblies
receive a final inspection and testing
prior to installation in the enclosure.
When installed, vibration isolation
pads are provided to isolate the core
and coil assembly from the base structure. All structural parts are grounded
to prevent induced voltage buildup.
Step-Lap Mitre Core Construction
Construction
FP transformers utilize a 220° C
insulation system that combines
inorganic materials and resins to
provide a fire resistant, high dielectric
capability. All materials have been
thoroughly tested and proven with
respect to their stability at required
operating temperatures.
The major components of the 220°
C system include Nomex® paper for
conductor insulation plus resin-glass
laminates, silicon rubber and polyester
varnish. The combination of materials
is specifically chosen to assure long
operating life and quiet operations
Nomex® is a Registered Trademark of
Dupont Co.
Taps
Primary windings are furnished with
full capacity tap connections to provide
adjustment to accommodate variations
in the incoming high voltage. All
units include, as standard, two (2)
2-1/2% taps full capacity above normal
(FCAN) and two (2) 2-1/2% taps full
capacity below normal (FCBN).
The tap connections are located in
a vertical arrangement on the side
of each coil. Accessible behind
removable covers, the taps can easily
be changed by moving jumpers
between connection points when the
transformer is de-energized.
Step-Lap Mitre Core
Construction
87
Unit Substation
The core legs are arranged in a
"stepped" configuration to accommodate the coils and to provide maximum
cooling and strength. The completed
three-leg core assembly is rigidly
clamped with steel members to prevent
movement and to provide support for
the coils.
Nomex® insulated wire-wound primary
windings are placed directly over the
secondary windings with a suitable
insulating barrier between the coils
consisting of spacers and sheet insulation applied to the proper thickness.
Primary windings may be randomwound or disc-wound depending upon
the design requirements. All coils are
adequately braced for full short circuit
capability.
Forced Air Cooled System
Forced-Air Cooled System
Operation
Unit substation transformers with selfcooled ratings of 300 KVA and above
can be supplied with fans and controls
to obtain additional KVA capacity.
Forced circulation of air correctly
applied permits the self-cooled
KVA rating of the transformer to be
increased by an additional 33-1/3%.
(Class FA rating)
2. Should the temperature increase to
200° C, the red light and remote
alarm (if connected) operate.
The winding temperature indicator
is furnished with three (3) sets
of normally open contacts. Each
contact closes as the average winding
temperature reaches factory preset
temperature values.
3. A further increase in winding
temperature to 210° C will operate
contacts that can be used to trip the
primary or secondary main breaker.
Sequence of operation is as follows:
1. When the winding indicator reaches
190° C (based on 150° C average
winding rise temperature in a
maximum 40° C ambient), the fan
relay is energized which closes the
fan-relay contact. The fans operate
resulting in 33-1/3% additional
KVA capacity.
Unit Substation
The winding temperature control panel
is equipped with necessary controls for
the operation of the fans:
1. Winding temperature indicator
2. Fan position test switch
3. Temperature sensing device
4. Fuses
5. Green light (auxiliary power "On")
6. Amber light (fan operation)
7. Red light (excessive temperature)
Temperature Gauge
88
Core and Coil Assembly 15 KV Class, Fan Cooled
Rating Information
Three Phase Transformer Standard Ratings
High
Voltage
Ratings
(Delta)
60 Hz
2400
High Voltage Taps
(Volts at Rated KVA)
+5%
+2-1/2%
-2-1/2%
-5%
2520
2460
2340
2280
4160
4360
4260
4055
3950
4800
5040
4920
4680
4560
6900
7245
7070
6730
6555
7200
7560
7380
7020
6840
12000
12600
12300
11700
11400
12470
13095
12780
12160
11845
13200
13860
13530
12870
12540
13800
14400
14100
13500
13200
Designs can be furnished to meet individual system requirements. Federal
Pacific construction incorporates high
short-circuit capabilities with the following BIL ratings:
Primary
Voltage
Class
IEEE
FP
Standard Standard
BIL
BIL
FP
Hi-Pulse
BIL
2.5 KV
20 KV
20 KV
30
5.0 KV
30 KV
30 KV
45
7.2 KV
45 KV
45 KV
95
15 KV
60 KV
60 KV
95
112-1/2
150
225
300
500
750
1000
—
—
—
300/400
500/667
750/1000
1000/1333
112-1/2
150
225
300
500
750
1000
1500
2000
2500
3000
—
—
—
300/400
500/667
750/1000
1000/1333
1500/2000
2000/2667
2500/3333
3000/4000
Unit Substation
BIL (Basic Insulation Level
Low Voltage Ratings 60 Hz
208Y/120
480Y/277
240
480\600\
KVA Ratings
Forced Air
Forced Air
Self Cooled
Self Cooled
Cooled
Cooled
(AA)
(AA)
(FA)
(FA)
Transformer Nominal Impedance and Sound Levels
KVA
Percent Impedance 3 Phase
5 kV Class
(30 kV BIL)
112-1/2 Consult Factory
150
Consult Factory
225
Consult Factory
300
5.00
500
5.75
750
5.75
1000
5.75
1500
5.75
2000
5.75
2500
5.75
3000
5.75
Audible Sound Levels (db)
15kV Class
(60 kV BIL)
Self Cooled
(AA) Average
Consult Factory
Consult Factory
Consult Factory
5.00
5.75
5.75
5.75
5.75
5.75
5.75
5.75
50
50
55
55
60
64
64
65
66
68
68
The standard rating for 15 kV class
dry-type transformers is 60 kV BIL.
Temperature Rise
Federal Pacific designed and
developed the Hi-Pulse Ventilated
Dry-Type Transformer which has
a basic insulation level of 95 kV
BIL. The application of a Hi-Pulse
Transformer in a 15 kV installation
eliminates the potential weak-link
and provides 58% additional surge
protection over the conventional
60 kV BIL dry-type transformer.
The 95 kV BIL ventilated dry-type
transformer provides a fully rated, air
insulated 15 kV installation
Designs are optionally available with
either 80° C or 115° C rise that can
provide long life performance per IEEE
C57.96 with lower losses and minimize
operating costs on systems with a
continuous high loading operation.
Forced Air
Cooled (FA)
Average
—
—
—
67
67
67
67
68
69
71
71
The rated KVA of a transformer is the
output based on average winding temperature rise above an average 30° C
ambient not to esceed 40° C during a one
(1) hour period. Standard transformers
are designed to operate with a 150° C
temperature rise.
89
Full Load Current Ratings
Three Phase Self-Cooled Transformers
KVA
Rating
112.5
150
225
300
500
750
1000
1500
2000
2500
3000
Unit Substation
KVA
Rating
112.5
150
225
300
500
750
1000
1500
2000
2500
3000
2400V
27.1
36.1
54.1
72.2
120
180
241
361
481
601
722
4160V
15.6
20.8
31.2
41.6
69.4
104
139
208
278
347
416
Secondary Full Load Current (Amperes)
208V
240V
480V
600V
312
271
135
108
416
361
180
144
625
541
271
217
833
722
361
289
1388
1203
601
481
2082
1804
902
722
2776
2406
1203
962
4164
3608
1804
1443
5551
4811
2406
1925
6939
6014
3007
2406
8327
7217
3608
2887
Three-Phase KVA =
90
Primary Full Load Current (Amperes)
4800V
7200V
12000V
12470V
13200V
13.5
9.0
5.4
5.2
4.9
18.0
12.0
7.2
6.9
6.6
27.1
18.1
10.8
10.4
9.8
36.1
24.1
14.4
13.9
13.1
60.1
40.1
24.1
23.1
21.9
90.2
60.1
36.1
34.7
32.8
120
80.2
48.1
46.3
43.7
180
120
72.2
69.4
65.6
241
160
96.2
92.6
87.5
301
200
120
116
109
361
241
144
139
131
Volts x Load Amperes x 1.7321
1000
13800V
4.7
6.3
9.4
12.6
20.9
31.4
41.8
62.8
83.7
105
126
14400V
4.5
6.0
9.0
12.0
20.0
30.1
40.1
60.1
80.2
100
120
Primary Switch Ratings
Type Auto-jet II ® Load Interrupter Switch Ratings
Maximum
Design
kV
Voltage Ratings
Withstand
60 Hz
BIL
kV
kV
Current Ratings
Fault
Momentary
Interrupting
Closing
Asym.
Amps
Asym. Amps
Amps
40,000
40,000
600
61,000
61,000
40,000
40,000
600
61,000
61,000
Continuous
Amps
5.0
19
60
600
15.0
36
95
600
3-Second
Short-Time
Sym. Amps
25,000
38,000
25,000
38,000
Suggested Minimum Current Limiting Fuse Ratings for Three Phase
Self-Cooled Dry-Type Transformers*
KVA
7200 V
12470 V
13200 V
13800 V
G.E.
Cutler
Hammer
G.E.
Cutler
Hammer
G.E.
Cutler
Hammer
G.E.
Cutler
Hammer
G.E.
Cutler
Hammer
40E
40E
65E
80E
125E
150E
200E
300E
375
400
25E
30E
45E
60E
100E
150E
200E
300E
400X
600E
30E
40E
50E
65E
100E
125E
150E
200E
—
—
15E
18E
25E
35E
60E
100E
125E
200E
250E
—
20E
20E
30E
40E
65E
80E
100E
125E
150E
175E
8E
10E
15E
25E
40E
60E
75E
100E
150E
175E
20E
20E
30E
40E
65E
80E
100E
125E
150E
175E
8E
10E
15E
20E
30E
45E
65E
100E
150E
175E
20E
20E
30E
40E
65E
80E
100E
125E
125E
150E
8E
10E
15E
18E
30E
45E
60E
100E
125X
175E
Unit Substation
112-1/2
150
225
300
500
750
1000
1500
2000
2500
4160 V
*Fuse selections are based on recommendations of the listed fuse manufacturers and are minimum sizes suggested to allow for transformer
magnetizing current inrush. Ratings are shown for the following types:
General Electric Co. — Type EJ-1 and EJO-1
Cutler-Hammer — Type CLE
Application Guide - Nominal System Suggested Arrester Rating†
Line-to-Line
Voltage
4160
4800
6640
7200
7620
8320
9960
11000
11500
12000
12470
13200
13800
14400
17250
19750
20780
22860
24940
26400
27700
34500
36200
4 Wire
Multi-Grounded
Neutral System
3
6
6
6
6
6
9
9
9
9
9
10
10
12
15
15
15
18
18
21
21
27
27
3 Wire Delta or WYE1
Low Impedance
High Impedance
Ground
or Ungrounded
6
6
6
9
9
9
9
10
10
12
12
12
12
15
15
18
18
21
24
24
27
30
36
6
6
9
9
9
10
12
12
15
15
15
15
18
18
21
21
24
27
30
30
30
36
—
Application of specified rating may be permissible for ungrounded or resistance grounded systems where a single phase ground may be
tolerated for a period of time not to exceed the arrester's power frequency overvoltage capability.
† Source: GE Buylog®, January 2008. Used by permission.
1
91
Approximate Dimensions and Weights - Indoor Only
USS Approximate Dimensions and Weights - Indoor Only (DOE 2010 Efficiency Compliant)
Data based on standard aluminum wound indoor transformer, having 480 volts low voltage. Contact factory for dimensions on NEMA 3R outdoor units.
Contact factory for depth dimensions on transformers having 208 volts low voltage.
150° C Rise (Indoor Only) 115° C Rise (Indoor Only) 80° C Rise (Indoor Only)
KVA
KVA
2190
2375
2500
2875
3325
5000
6125
7550
9940
10430
13750
112.5
150
225
300
500
750
1000
1500
2000
2500
3000
KVA
15kV- 60kV BIL
H W D
Wt.
(in.) (in.) (in.) (lbs.)
112.5
150
225
300
500
750
1000
1500
2000
2500
3000
90
90
90
90
90
90
90
90
102
102
110
112.5
150
225
300
500
750
1000
1500
2000
2500
3000
Unit Substation
5kV - 30kV BIL
H W D
Wt.
(in.) (in.) (in.) (lbs.)
90
72
90
72
90
72
90
72
90
78
90
78
90
78
90
90
90 102
90 102
102 112
78
78
78
78
90
90
90
102
112
112
120
48
48
48
48
48
48
48
48
58
58
58
48
48
48
48
58
58
58
58
58
58
58
2450
2500
2925
3700
5040
6290
7540
8810
11400
12000
14950
5kV - 30kV BIL
H W D
Wt.
(in.) (in.) (in.) (lbs.)
90 72
90 72
90 72
90 78
90 78
90 78
90 78
90 90
90 102
102 102
102 112
48
48
48
48
48
48
48
48
58
58
58
KVA
5kV - 30kV BIL
H W D
Wt.
(in.) (in.) (in.) (lbs.)
2245
2425
2550
2950
3450
5050
6150
7615
10000
11275
13900
112.5
150
225
300
500
750
1000
1500
2000
2500
3000
KVA
15kV- 60kV BIL
H W D
Wt.
(in.) (in.) (in.) (lbs.)
KVA
112.5
150
225
300
500
750
1000
1500
2000
2500
3000
90
90
90
90
90
90
90
90
102
110
110
15kV- 60kV BIL
H W D
Wt.
(in.) (in.) (in.) (lbs.)
112.5
150
225
300
500
750
1000
1500
2000
2500
3000
90
90
90
90
90
90
90
102
102
110
110
78
78
78
78
90
90
90
102
112
112
120
48
48
48
48
58
58
58
58
58
58
58
2690
2750
3125
3950
5200
6450
7700
8920
11700
13580
16250
90 72
90 72
90 72
90 78
90 78
90 78
90 78
90 90
102 102
102 112
102 112
78
78
78
78
90
90
90
112
112
112
120
48
48
48
48
48
48
48
48
58
58
58
48
48
48
48
58
58
58
58
58
58
58
2275
2450
2575
3000
3500
5100
6175
8420
10025
12125
14125
H
W
D
2950
3000
3375
4190
5400
6900
8400
9940
12900
14170
17650
I. Air-Filled Terminal Compartment - Low Voltage Outgoing Line Section
The depth and height of the air-filled cable terminal compartment will match the corresponding
ventilated dry-type transformer dimensions.
Voltage
Class
600V
Cable
Termination
Clamp-type
Width
(Inches)
18
H = 90"
350
Weight (lbs.)
H = 102" H = 110"
440
470
H
II. Air-Filled Terminal Compartment - High-Voltage Incoming Line Section
(HV Switch Not Required)
Air-Filled
Terminal
Compartment
D
W
The depth and height of the air-filled terminal compartment will match the transformer.
Voltage
Class
Cable Termination
Clamp-type
5 kV
Clamp-type with Lightning Arresters
30 kV BIL
Pothead (3/1/C or 3/C)
Clamp-type
15 kV Clamp-type with Lightning Arresters
60 kV BIL
Pothead (3/1/C or 3/C)
Width
(Inches)
18
18
18
18
18
18
Weight (lbs.)
H = 90" H = 102" H = 110"
360
400
425
360
400
425
360
400
425
360
400
425
360
400
425
360
400
425
H
Air-Filled
Terminal
Compartment
D
W
III. Non-Segerated Cable Termination Area (Indoor - Cable Entrance: Top or Bottom Outdoor - Cable Entrance: Bottom only)
• Non-Segregated Cable Termination Area is an alternate to Air Terminal Chamber.
• For the width dimension of a transformer with a Non-Segerated Cable Termination Area (HV only, LV only, both HV & LV), use the width dimension of the next KVA size up.
IV. The Auto-jet® Switch Compartment (HV Air Filled Terminal Compartment Not Required)
Voltage
Class
Height
(Inches)
90
Two position switch and CL fuse
5 kV
Two
position
switch,expulsion
fuse,
arresters
90
60 kV BIL
Two position switch, CL fuses and arresters
90
Two position switch and CL fuse
90
15 kV Two position switch,expulsion fuse, arresters
90
95 kV BIL
Two position switch, CL fuses ad arresters
90
Cable Termination
Width1
(Inches)
36
41
36
36
41
36
For a side entry termination cabinet add 20 inches to the width.
For a rear entry termination cabinet add 16 inches to the depth.
Depth2
(Inches)
46
46
46
46
46
46
Weight (lbs.)
1200
1000
1300
1300
1200
1400
H
Incoming HV
Switch
Compartment
1
2
92
W
D
Specification Guide
General Specification Guide
The transformer shall be ventilated,
open,dry-type construction cooled by the
circulation of air through the windings.
The unit shall be mounted in an indoor or
outdoor enclosure finished in the manufacturer’s standard ANSI 61 light gray paint
with provisions for direct connection to
the primary and secondary equipment as
specified.
The transformer shall be designed, manufactured, and tested in accordance with
the applicable NEMA, ANSI, and IEEE
standards
The facility in which the transformers are
manufactured shall be an ISO 9001:2000
registered facility.
Basic Rating
Insulation Materials
All insulation materials for the primary and
secondary coil assembly shall be rated for
continuous 220° C total temperature (Class
H).
Insulation on the rectangular wire conductor shall be Nomex® or equivalent, which
has a UL Listed 220°C insulation system
having suitable overlapping to keep dielectric volts/mil stress within limits recommended by the insulation supplier.
Layer insulation for LV strip windings shall
be Nomex® or equivalent, which is in a UL
Listed 220°C insulation system having a
thickness to keep volts/mil stress values no
higher than values recommended by the
insulation supplier.
Final Dip and Bake
Upon completion of the VPI process of
the coils and their assembly on the core,
the core top yokes are stacked, the core is
clamped and all necessary leads are welded
(if aluminum) or brazed (if copper) to the
LV and MV bus components. At this time
the complete core and coil assembly is
dipped into a soft solvent based varnish
of Isonel® 51 or equivalent to provide a
protective coating from oxidation for all
bare metal parts like core laminations and
core clamping hardware. The varnish used
for this process must not be a hard varnish
like a 100% solids material. This core and
coil assembly is then baked at the proper
time and temperature (usually 4-8 hours @
175°C) to cure all of the varnish.
Transformer Enclosure and Base
The core shall be constructed of non-aging,
cold-rolled, high permeability silicon steel.
All core laminations shall be step-lap mitred cut, free of burrs and stacked without
gaps. The core framing structure shall be
of rigid construction to provide full clamping pressure upon the core and provide the
support points for the coils. Butt lap construction shall not be acceptable for power
ratings above 1000 KVA.
The HV and LV coils shall be cylindrically
wound (not rectangular) as an assembly
with the HV coil wound directly over the
LV coil. Coils shall be adequately braced
for full short circuit capability to pass
short circuit tests in accordance with IEEE
C57.12.91.
The transformer base shall be welded construction and shall be constructed to permit
4 point lifting using 1-1/2” diameter and
1” thick lifting eyes along the base of the
transformer. The enclosure shall include
provisions for rolling, skidding, lifting, and
jacking for installation.
Removable panels shall not exceed 70
pounds in weight and shall contain suitably
strong handles for lifting and placing. If
installation space is adequate, hinged doors
may be provided, when specified.
The enclosure shall be constructed of heavy
gauge sheet steel equipped with removable
parts for access to the core and coils on the
front and rear. Ventilated openings shall be
furnished to meet NEMA standards. The
cabinet metal must be at least 14 gauge
thickness. Whenever the cabinet must be
outdoors (NEMA 3R) the ventilation openings must be constructed as “back-to-back”
channels as shown in the NEMA 3R Unit
Substation Photograph on page 83 of the
Federal Pacific Transformer Catalog. (For
NEMA 3R Lip Slots for ventilation are not
acceptable).
Paint for the transformer enclosure shall
be an ANSI-61 light grey color of a polyurethane powder coating that is electrostatically applied conforming to UL 1332
specifications. For installation areas within
highly corrosive environments stainless
steel enclosures may be furnished as an option as shown in Item 13(a) of the Transformer Specification Checklist Page.
VPI Process for transformer coils:
The coil assembly is baked for 2 hours at
190° C to remove moisture. Preheated
The manufacturer of the Unit Substation
Transformer shall be responsible for all the
drawings and mechanical provisions for
Core and Coil Assembly
the proper coordination and attachment of
the closely coupled switchgear on both the
HV and LV ends of the transformer. Special
attention needs to be given to item 14 in the
Transformer Specification Checklist page
for this requirement.
Vibration dampening pads shall be provided to isolate the core/coil assembly from
the base structure.
High Voltage Taps
Each coil shall have taps at nominally rated
voltage and an additional 4 taps: 2-2-1/2 %
above and below rated nominal voltage.
Tap leads shall be terminated at the coils
and equipped with provisions for changing
taps under de- energized conditions.
Sound Level
The transformer shall be designed to meet
the sound level standards for dry-type
transformers as defined in IEEE C57.12.01
-1998 or NEMA ST-20.
Forced-Air Cooling
(Refer to the Transformer Specification
Checklist Page, Item 3)
When forced-air cooling is specified,
the forced-air cooling package (fans and
controller shall be provided for automatically increasing the self-cooled rating by
33-1/3%. The system shall contain 120 VAC
single phase fans and a control panel with
indicating lights, temperature indicator, fan
position test switch, and alarm mode selector switch.
Accessories as specified
(Refer to Basic Medium Voltage Open Dry
Transformer Rating Information.)
Winding Temperature Controllers and
Monitors shall be Qualitrol or equivalent.
Provisions for grounding shall be provided
to be welded Ground Pads or special termination hardware.
Final Tests
Final Test Reports in the proper IEEE format can be furnished for each unit upon request, documenting the successful passing
of all required testing.
Optional Testing may be specified in the
Basic Medium Voltage Open Dry Transformer Rating Information.
93
Unit Substation
(Refer to the Transformer Specification
Checklist Page, Items 1-12, for specifying
basic ratings).
coils are placed in a sealed VPI pressure/
vacuum tank and impregnated with a 100%
solids varnish in accordance with the process described on page 99 of the Federal
Pacific Transformer Catalog.
Basic Medium Voltage Open Dry Transformer Rating Information
Ship To Destination:
City ________________________________________________________________________ State ________________________
Customer Name: ____________________________________________________________________________________________
Power Rating Self-Cooled (AA)
________________ KVA
q Three Phase
Power Rating Self-Cooled (AA/FA) ________________ KVA
(If fans are required)
q Single Phase
Frequency:
q 60 Hz
q 50 Hz
UL® Listed:
q Yes
q No
Primary Transformer Protection (check one)

HV Fused Switch

Customer will buy NEW Switch or VCB

Vacuum Circuit Breaker (VCB)

Customer will use EXISTING Switch or VCB

Other
Enclosure:
Unit Substation
q Indoor (NEMA 1)
Special K-Factor
q Yes
q No
q Outdoor (IEEE 103R)
Fans or Provisions for Fans Required: q Yes q No
q Furnish 1ø CPT (480V OR 208V) with Fans
q No CPT Power for Fans and controller by others
q Provisions for fans (no wiring, no controller)
q Provisions for fans (with wiring, no controller)
q Provisions for fans (with wiring, with controller)
Sound Level:
q K-4
q STD
q K-9
q K-13
DOE 2010 Energy Efficient (USA Requirement)
C800.02.06 Energy Efficient (Canadian Only)
q Delta q Wye
BIL in kV: _________________
Secondary Voltage: ______________________ Volts
q Delta q Wye
BIL in kV: _________________
HV Taps:
q 150
q 115
q 80
q Other
q Special Sound in db:
Primary Voltage: ________________________ Volts
Average Winding Temperature Rise °C:
q K-20
q Yes
q Yes
q No
q No
q Other
q Standard Full Capacity: 2-2-1/2% Above and 2-2-1/2% Below Rated Primary Voltage
q Other Taps
Impedance: q Standard q Other _____________________________________________________________________________________________
Windings:
q Aluminum
q Copper
Electrostatic Shield Between Primary and Secondary Windings:
q Yes
q No
Transformer Construction
q High Voltage General Purpose, HVGP ("Cable In" and "Cable Out' without Air Terminal Compartments) q Stub Up
q Stub Down
q Unit Substation
Unit Substation Primary Side
q Close Coupled to Switchgear (Flange)
q Full Height Terminal Chamber
q Non-Segregated Cable Termination Chamber
q Throat
q Bolted Panel Only
Unit Substation Secondary Side
q Close Coupled to Switchgear (Flange)
q Full Height Terminal Chamber
q Non-Segregated Cable Termination Chamber
q Throat
q Bolted Panel Only
q Pad-Mount Tamper Resistant Low Profile per IEEE C57.12.28
q Core and Coil Replacement
Seismic Bracing Required:
If "Yes":
94
q Zone 1
Height" ____________________ Width"_______________________ Depth" _____________________________
q Yes
q Zone 2
q No
q Zone 3
q Zone 4
q Other
Basic Medium Voltage Open Dry Transformer Rating Information
TESTING:
Standard (IEEE C57.12.91)
q Yes
Optional Special Tests q Yes
q No
q No
QC Impulse
IEEE C57.12.91 Impulse
Audible Sound
Heat Run (Temperature)
Partial Discharge
Other
q Yes
q Yes
q Yes
q Yes
q Yes
q Yes
q No
q No
q No
q No
q No
q No If Yes Please Specify ___________________________________________________
Primary Arresters
Secondary Arresters
q Distribution kV _________________________
q Intermediate kV ____________________
q Intermediate kV ________________________
q Station kV ________________________
q Station kV ____________________________
Unit Substation
q Distribution kV _____________________
Other Features
VPI Coils
VPI Coils with Epoxy Shield
Copper Ground Bus
Altitude Above 3300 Feet
Digital Temperature Monitor
Space Heaters With Thermostat
Dust Filters
Rodent Proofing
q Yes
q Yes
q Yes
q Yes
q Yes
q Yes
q Yes
q Yes
Losses Needed With Quotation q Yes
q No
q No
q No
q No
q No Altitude in _____________________ Feet
q No
q No
q No
q No
q Typical
q Guaranteed
NL Watts ___________________________
Load Watts _________________________
Total Watts __________________________
Dimensions Needed With Quote q Yes q No
Height in inches _________________
Width in inches __________________
Depth in inches __________________
Weight Needed With Quote q Yes
q No
95
Unit Substation
Typical Pad-Mount Transformer Configuration
96
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