Liquid Filled Secondary Substation Transformers SPECIFYING TRANSFORMERS The available incoming power supply determines the primary voltage and the frequency of the transformer. The voltage that is required by the load determines the secondary voltage. Present load, plus allowance for growth, determines the kVA rating of the transformer. Transformers with specific combinations of voltages and kVA ratings are available as standard designs. All secondary substation transformers are three-phase, 60 Hz, with high-voltage windings delta-connect- ed. Transformers are also available in 50 Hz designs. STANDARD kVA RATINGS 225 kVA 1000kVA 300 kVA 1500 kVA 500 kVA 2000 kVA 750 kVA 2500 kVA 3000kVA The standard kVA ratings are based on a 65oC average winding temperature rise by resistance above a 30oC average ambient. STANDARD PRIMARY VOLTAGE RATINGS All Delta: 2400 Volts* 12000 Volts 4160 Volts 12470 Volts 4800 Volts 13200 Volts 6900 Volts 13800 Volts 7200 Volts *Not available above 1500 kVA. Primary voltage ratings are supplemented with four approximately 21/2 percent full-capacity taps, two above and two below normal. This combination allows compensating for either a higher or a lower than normal sustained primary voltage. STANDARD SECONDARY VOLTAGE RATINGS ** 208Y/120240 480 480Y/277 * Not available above 1500 kVA Secondary voltage ratings are approximately 4.2 percent above the standard motor voltages (460 and 230 volts), allowing for voltage drop in the line between the substation and the motor terminals without operating the motor at subnormal voltage. Motors and control operate satisfactorily on voltages 10 percent above or below rating. Secondary lighting voltages are standardized at the voltage rating of the lamps (120 volt). Operating voltage is fairly critical to lamp performance. Overvoltage causes overheating and subsequent short life of lighting equipment, while undervoltage reduces illumination output and may have adverse effects on the operation of fluorescent lamps. The 120-volt rating for lighting transformers normally gives the best results. If the regulation is then too great, it is the usual practice to correct it with a small voltage regulator installed on each feeder. PRIMARY SECONDARY kVA LINE-TO-LINE VOLTS LINE-TO-LINE VOLTS 2400 4160 4800 6900 7200 12000 12470 13200 13800 208 240 480 600 112.5 27.1 15.6 13.5 9.4 9.0 5.4 5.2 4.98 4.7 312 271 135 108 150 36.1 20.8 18.0 12.6 12.0 7.2 6.9 6.6 6.3 416 361 18. 144 225 54.1 31.2 27.1 18.8 18.0 10.8 10.4 9.8 9.4 625 541 271 217 300 72.2 41.6 36.1 25.1 24.1 14.4 13.9 13.1 12.6 833 722 361 289 500 120 69.4 60.1 41.8 40.1 24.1 23.1 21.9 20.9 1388 1203 601 481 750 180 104.1 90.2 62.8 60.1 36.1 34.7 32.8 31.4 2082 1804 902 722 1000 241 139 120 83.7 80.2 48.1 46.3 43.7 41.8 2776 2406 1203 962 1500 361 208 180 126 120 72.2 69.4 65.6 62.8 4164 3608 1804 1443 2000 278 241 167 160 96.2 92.6 87.5 83.7 2406 1925 2500 347 301 209 200 120 116 109 105 3007 2406 3000 416 361 251 241 144 139 131 126 3608 2887 TABLE OF LINE CURRENTS Cooling Panels 38” Depth 38” Flange to Flange HV Coordinations: • Power Vac • HV Air Switch • Busduct OR Optional HV Air Terminal Compartment (Heaters and Arresters Available) 90” OR Height OR 90” Optional LV Air Terminal Compartment (Heaters Available) OR LV Coordinations: • AKD-8/AKD-10 • Power Break • Spectra Busway • Switchboard Mebane • Switchboard Houston • Limit Amp Mebane • Motor Control Mebane • Busduct 26” 26” High Voltage Transformer Front View Low Voltage Dimensions and weights are subject to change without notice and should not be used for construction purposes. APPROXIMATE WEIGHT (Lbs.), VOLUME (Gallons), AND DIMENSIONS (Inches) (Oil Filled; 65oC Rise; HV Copper; LV Aluminum) KVA* Height Flange to Flange Depth Oil Weight 750 94 49 66 220 6,800 1,000 94 54 66 300 9,000 1,500 94 58 70 350 9,600 2,000 94 60 72 360 10,500 2,500 95 62 86 400 13,000 3,000 99 65 94 480 15,600 APPROXIMATE WEIGHT (Lbs.), VOLUME (Gallons), AND DIMENSIONS (Inches) (Silicone Filled; 65oC Rise; HV Copper; LV Aluminum) KVA* Height Flange to Flange Depth Oil Weight 750 98 49 66 220 6,900 1,000 98 54 70 310 8,200 1,500 98 58 74 320 9,700 2,000 98 60 80 360 11,900 2,500 98 62 88 410 13,400 3,000 99 65 104 490 15,900 APPROXIMATE WEIGHT (Lbs.), VOLUME (Gallons), AND DIMENSIONS (Inches) (Oil Filled; 55/65oC Rise; HV Copper; LV Aluminum) KVA* Height Flange to Flange Depth Oil Weight 750 94 49 66 240 7,000 1,000 94 54 66 310 8,400 1,500 94 58 72 360 10,000 2,000 94 60 88 400 12,100 2,500 96 62 96 420 13,700 3,000 99 65 104 490 16,100 APPROXIMATE WEIGHT (Lbs.), VOLUME (Gallons), AND DIMENSIONS (Inches) (Silicone Filled; 55/65oC Rise; HV Copper; LV Aluminum) KVA* Height Flange to Flange Depth Silicone Weight 750 98 49 70 230 7,100 1,000 98 54 72 320 8,600 1,500 98 58 91 330 10,100 2,000 98 60 96 370 12,300 2,500 99 62 104 430 14,000 3,000 99 65 110 500 16,400 Dimensions and weights are approximate for kVA, 15kV Class, 95 kV BIL and normal service conditions. Flange to flange dimensions may decrease slightly for Class units, with LV of 5 kV. Dimensions may vary with special requirements. * ForKVA’s not listed, contact the factory. Percentage Impedance 225 2.0* 300-500 4.5* 750-3000 5.75• STANDARD IMPEDANCES kVA * Minimum impedance • 5.5% above 600VLV AUDIO SOUND LEVELS All transformers have an inherent sound caused by the alternating magnetic flux in the core. The sound level is proportional to the kVA size of the transformer. There are a variety of options to compensate for sound issues. For example: 1. Strategically locate sites tominimize noise issues. 2. Use flexible conduit connectionsto prevent sound from being transmitted to other locations. Use auxiliary vibration dampers when appropriate. 3. Design transformer rooms so thatthey will minimize sound. 4. Install the transformer away fromsmooth surfaces, hallways, stairways, and enclosures which may reflect, resonate, or echo the sound. STANDARD SOUND LEVELS SELF COOLED RATING kVA WITHOUT FANS WITH FANS RUNNING 300 & LESS 55 . . 500 56 . . 750 58 67 1000 58 67 1500 60 67 2000 61 67 2500 62 67 3000 63 67 PROVISION FOR FAN COOLING Cooling fans will increase the transformers capacity by 15 percent (750-2499 kVA) and 25 percent (2500-3000 kVA). Includes: 1. Capacity in all current-carryingparts for fan-cooling rating. 2. Thermometer relay to control fan from liquid temperature. Low- System BIL Insulation frequency Classs kV kV kV kV Kv kV Crest Crest Micro- Seconds 1.2 30 1.2 10 36 1.0 30 2.4 45 2.5 15 54 1.5 45 4.8 60 5 1.5 60 8.32 75 8.7 26 88 1.6 75 14.4 95 15 34 1.8 95 Typical Impulse Test Voltage Test Chopped Wave Full Wave Min. Time to Flashover, 19 69 110 2400 4160 4800 6900 7200 12000 12470 13200 13800 Primary H2 H3H1 Secondary X2 X1 X3 XN 208Y/120 three- or four-wire 480/277 three- or four-wire Delta-Delta connections 2400 4160 4800 6900 7200 12000 12470 13200 13800 Primary H2 H3H1 Secondary X2 X3X1 240 three wire 480 three wire(Three Wire) (Three Wire) Voltage Delta-Wye connections Voltage Liquid- Filled Impulse Ratings Nominal SYSTEM Voltage, kV Standard BIL, kV Optional BIL, kV 1.2 2.5 5 8.7 15 30 45 60 75 95 45 60 75 95 110 Delta-connected primary windings are provided in standard secondary substation transformers. This is the simplest and most satisfactory connection. Wye-connected secondary windings gain the advantages of neutral grounding in the most practical and economical manner. DESIGN Thorough analysis by GE Prolec designers incorporate many new features utilizing state of the art technology. The result: high mechanical and electrical strength necessary to meet the latest ANSI C57.12.90. This is the standard test code and guide for short-circuit testing of transformers. Liquid-filled transformers are available with three types of dielectric fluid: oil, silicone and R-TEMP or equal. All types are enclosed in sealed tanks to keep the internal elements free from dirt, moisture and corrosive atmospheres. OIL-FILLED The oil-filled unit is the least expensive transformer, and is suitable for mounting outdoors or indoors enclosed in a vault. The oil used in GE Prolec transformers meets all the requirements of ANSI C57.106 and ASTM D3487, has high dielectric strength, is free from impurities, is durable and has a high flash point. These features make it an excellent insulating liquid. SILICONE-FILLED The silicone fluid selected for use in GE Prolec transformers is a clear, liquid silicone polymer (polydimethylsiloxane) that has been specially processed to meet exacting dielectric specifications. To obtain an optimum combination of heat transfer and fireresistant properties, the transformer silicone fluid has a viscosity of 50 centistokes at 25oC. This fluid has a minimum fire point of 300oC and oxygen index of 21. The silicone fluid that we are using meets paragraph 450-23 (Less- Flammable Liquid-Insulated Transformers) of the National Electrical code. OSHA by its Program Directive 100-68 permits the use of silicone transformers as equivalent to askarel transformers in its enforcement of the National Electrical Code. Transformer silicone fluid has suitable dielectric characteristics, is compatible with other materials used in construction of transformers, and has shown good thermal stability in accelerated aging tests with transformer materials. LESS-FLAMMABLE DIELECTRIC LIQUID R-TEMP OR EQUIVALENT A Fire Resistant Hydrocarbon Fluid (FRHF) dielectric coolant formulated for use in distribution transformers is available when its unique electrical, thermal and safety properties are advantageous. It is non-toxic and readily biogradable. It is also referred to as a High Fire Point Fluid, a High Molecular Weight Hydrocarbon or a Less-Flammable Dielectric Liquid. The dielectric coolant is a listed less-flammable fluid meeting the requirements of National Electrical Code Section 450-23, including a minimum fire point of 300oC and the requirements of the National Electrical Safety Code (IEEE C2-1993), Section 15. CORE-AND-COIL CONSTRUCTION GE Prolec transformers are built with rectangular windings and core. The rectangular winding construction Film-insulated wire is used because it is less bulky than paper, has higher dielectric strength on a volts-per-mil basis, and does not tend to split or crack when small radius bends are made. To provide insulation between each layer in the high voltage windings, an electrical-grade adhe- sive-coated paper is used. After completing the winding process the high and low voltage coils are clamped to the desired dimensions. They are then oven baked at a temperature which allows the adhesive coating on the paper to bond the adjacent conductors and wires together. The result is a winding structure which has high short-circuit strength and high electrical stress withstand capability. The transformer cores are conreduces the size of the tank that structed of non-aging, high grade, results in savings in weight and floor grain oriented silicone steel laminaspace without compromising tions with high magnetic performance and quality. permeability. Magnetic flux densities are kept well below First, the low-voltage coils are the saturation point. Core wound on a rectangular form that laminations are free of burrs and simulates the rectangular core leg assembled without gaps. The and serves as the main support for core clamping brackets are all the windings. These coils are of designed to provide an even dissheet winding construction using tribution of clamping forces to the strip conductors. An extra strong core yokes and legs. electrical-grade paper is used as the insulation between each low-voltage turn. The high-voltage coils are wound, under tension, over the low-voltage coils and are of layer-wound construction using film-insulated wire. LEAK-RESISTANT WELDED TRANSFORMER TANK CONSTRUCTION The tank design incorporates many desirable features which assure flexibility of location, ease of maintenance and installation, and rodent protection. The design, in effect, wraps the tank around the core-and-coil assembly. In so doing, the overall weight is reduced by reducing the tank material weight as well as the weight of the dielectric fluid. The underside of the tank is accessible from the front and back, and allows the free movement of air, which helps to keep the underside of the tank dry and deter the formation of rust. The high and low voltage bolted flanges have no openings, which eliminates the possibility of rodent access to adjacent high and low voltage terminal equipment. The tank cover is welded-on to eliminate contamination in the atmosphere from entering the tank. Cooling-panels are leak tested during the production cycle. Sealed tank construction is achieved by seam welding formed and punched steel plates. Additional braces are welded as necessary to the side-walls to provide adequate pressure and vacuum ratings. Cooling panels are welded (removable radiators available) to the front and rear tank walls. Tanks are designed for 12 PSI. The tank is leak tested prior to, as well as after, coil drying and vacuum filling. Secondary substation transformer tanks feature side wall high voltage and low voltage bushings with flanges for connections to HV or LV switchgear or air terminal compartments. For ease of handling and installation sturdy lifting lugs are welded in place on each corner for lifting by crane. BUSHING DESIGN The bushing design utilizes bolted construction using time-tested gasketing techniques and materials which are compatible with the liquid dielectric. These techniques assure leak-free performance for the full life of the transformer. Both high and low voltage bushings are externally removable without the necessity of removing the tank cover. This enables easy replacement of the bushings, should such a replacement be required. The bolted-on porcelain or epoxy bushings are ideally suited for their application. GE Prolec provides transformers designed for standard arrangements or reverse arrangement whichever is most convient for installation. connections is with clamp type ter-B Non-corrosion diagrammatic minals (#2-4/0 AWG,250-500 nameplate MCM or 600-1000 MCM). B ANSI 61 paint finish, 5 mils thick 6. NEMAtwo hole lugs are available upon request. Optional Liquid and 7. GE Tranquell Intermediate, Distribution, and Station type Features arresters are available when specified. B Silicone fluid B High fire point fluid, such as R-TEMP. Standard Liquid and B 55/65oC Average Winding Rise The base is designed with bolt holes Features B Forced Air Cooling for easy tie down. It is constructed B Future Fan Wiring and Control for rolling, skidding or sliding in the B Type I Insulating mineral oil B Removable Radiators direction of either centerline. B 60 Hertz Operation B Pressure Relief Device B Externally operated de-energized B Fault Pressure Relay tap changer providing (2) 21/2 % B Winding Temperature Device Air Terminal Full Capacity taps above and B Devices with alarm contacts Compartments below Nominal B Top Filter Press Valve B 65oC Average Winding Rise B HV & LV Air Terminal 1. Terminal boxes can be supplied on B Side-mounted bushings Compartments the primary or secondary side of B HV and LV flange connections B HV lightning arresters in ATC the transformer. B Pressure-vacuum gauge B Current Transformers 2. HVterminal boxes are suitable for B Top filter press connections B Neutral Grounding Resistor single or loop feed. 3. Bolted-on end panel provides easyB Liquid level gauge access to the cable fittings. B Liquid temperature gauge Special Design or 4. Incoming line cables can enter theB Pressure test valve Application top or bottom of the terminal box B ANSI Grounding pad and can be connected with up to 8 B Drain/filter valve with sampling B Special Impedances cables per phase. 5. The standard method for cable device B Low Loss B Tank lifting lugs B Rectifier Transformer B Isolation Transformer B Special Ambient B Special/Low Sound Level B 50 Hertz B Seismic Zone III and IV B Retrofit to Specific Dimensions B Non-standard loading conditions such as harmonic loading or specified K-factor The liquid-level gage, dial-type thermometer, and pressure-vacuum gage are grouped with the nameplate so that all are easily readable from one floor-level position. OPTIONAL ACCESSORIES Winding Temperature Indicator The winding temperature indicator provides a visual reading of the equivalent transformer winding hotspot temperature. Similar to the top liquid thermometer, the winding temperature indicator is located in the top liquid. The indicator reads the combination temperature of the top liquid and a heater. This heater, when supplied with current proportional to the winding current, is designed to closely approximate the winding hotspot rise over the top liquid; and thus, the indicator reading indicates winding hot-spot. The indicator comes equipped with two sets of contacts which can be used for actuating auxiliary devices. Fault-Pressure Relay The fault-pressure relay provides a positive and reliable means of detecting an excessive rate of pressure rise within the tank resulting from an internal arc. The relay is normally mounted on the transformer cover. The relay is equipped with one normally open and one normally closed momentary contacts; therefore, the user must provide for a seal-in circuit to operate other devices. Pressure-Relief Device The pressure-relief device is selfreclosing and self-resealing. The mechanism is set at the factory to operate within an accuracy of plus or minus 10 percent. A pressure-relief device will be furnished as a standard accessory on all silicone-insulated transformers. PAINT FINISH Metal surfaces are thoroughly cleaned of scale, oil, grease, rust and other foreign matter prior to painting. They are spray painted with one coat of primer. An intermediate flow coat of enamel is then applied. If the unit is for outdoor application a third flow coat is applied to give a minimum film thickness of five mils. Final finishes use an air dry enamel which is applied by either the hot air spray or conventional cold spray methods. The standard paint finish color is ANSI-Number 61, Light Gray, Munsell Notation 8.3G 6.10/0.54. STANDARD TESTS The following tests will be made on all transformers but not necessarily in the sequence listed. All tests are performed in accordance with the latest revision of ANSI Standard Test Code for Transformers C57.12.90—- 1980. 1. Resistance measurements of all windings. 2. Ratio tests on the rated voltage connection and on all tap connections. 3. Polarity and phase-relation tests on the rated voltage connection. 4. No-load loss at rated voltage on the rated voltage connection. 5. Exciting current at rated voltage on the rated voltage connection. 6. Impedance and load loss. 7. Applied potential tests. 8. Induced potential tests. 9. Impulse tests. GUIDE FORM SPECIFICATIONS GENERAL ARRANGEMENT This specification covers a complete three phase secondary substation-type transformer. The transformer shall be (Check One) (__) Standard Arrangement; When facing the front (nameplate) of the transformer, the incoming section shall be on the left and the outgoing section on the right. (__) Reverse Arrangement; When facing the front (nameplate) of the transformer, the incoming section shall be on the right and the outgoing section on the left. RATING Three-phase substation shall have the following self-cooled ratings: kVA :__________ 300-3750 kVA with LV rating of <601 volts. 750-5000 kVA with LV rating of >600 volts. WINDING RISE : (__) 65 degree Centigrade rise…..(Standard). (__) 55/65 degree Centigrade rise. Allows for 12% additional capacity when operated at 65 degree Centigrade. FAN COOLING: (__) OA, self-cooled; No fans available <750 kVA. (__) OA/FFA self-cooled/future fan cooling capacity. (__) OA/FA, self-cooled / fan-cooled increased capacity: (15% additional capacity….750 kVA-2000 kVA) (25% additional capacity….2500 kVA-5000 kVA) FREQUENCY: (__) 60 Hertz (Standard) (__) 50 Hertz INSULATING FLUIDS: (__) Mineral Oil (__) Silicone (__) High fire point fluid (ex. R-Temp) HV Rating: (__) __________ Delta or Wye * LV Rating: (__) __________ Wye * or (__) Delta * HVWye-LV Wye available only for 2500 KVA and below. HV BIL: (__) Standard….HV 15 kV Class, 95 kV BIL; 5 kV Class, 60kV BIL (__) Optional….HV 15 kV Class, 110 kV BIL; 5 kV Class, 75kV BIL LV BIL: (__) Standard….LV 480 V Class, 30 kV BIL; 5 kV Class, 60kV BIL (__) Optional….LV 480 V Class, 45 kV BIL; 5 kV Class, 75kV BIL Impedance: (__) Standard….5.75 % for LV 7 600 V above 501 kVA; 7 501 kVA 4.5 % Min or 5.50 % for LV 9 600 V and HV BIL = 110kV (__) Special _______ Note: ANSI allows the tested Impedance to vary 7.5 % above or below the designed Impedance. GENERAL CONSTRUCTION The liquid insulated, secondary type substation transformer shall be designed, manufactured and tested in accordance with the latest ANSI Standards. Impedance, sound level and voltage connections shall be in accordance with NEMA Standards. The core shall be constructed of high-grade gain oriented silicone steel laminations to reduce size, sound and losses. The coils shall be of rectangular construction utilizing extra strong, electrical grade, adhesive-coated paper between turns. The core and coil assembly shall be installed in a sealed tank, immersed in insulated liquid to prevent dirt, moisture and corrosive elements from deteriorating the electrical and mechanical integrity of the transformer. Transformer shall have four approximately 2.5 percent rated kVA taps, two above and two below rated primary voltage. These taps shall be available by means of an externally operated manual tap changer for operation only when transformer is de-energized, with provisions for padlocking the tap changer. STANDARD FEATURES Windings : HV Cu / LV Al Provisions for lifting and jacking Cover vent plug Drain and sampling device Top filter-press connection 12-PSI tank Liquid level gauge Pressure test valve Two tank grounding pads Pressure vacuum gauge Anodized aluminum Nameplate Dial type thermometer (liquid) Tank hand hole on transformer cover Pressure relief device (Silicone units) ANSI 61 Gray finish coat paint No load tap changer with handle on front wall of transformer OPTIONAL FEATURES (__) Windings: All Copper (__) Pressure relief device * (__) Fault pressure relay * (__) Winding temperature indicator * (__) Pressure relief device (Oil Units) * (__) Liquid level gauge * (__) Liquid temperature indicator * (liquid) * Device with electrical contacts INCOMING SECTION (__) HV flange, 90” full-height (Standard) (__) Air filled terminal compartment: 26.4”deep and 38.4” wide. Compartments are full height. Space heaters standard in outdoor units. (__) Coordinated to HV Switch (supplier) _______ OUTGOING SECTION (__) LV flange, 90” full-height (Standard) (__) Air filled terminal compartment: 26.4” deep and 38.4” wide. Compartments are full height. Space heaters standard in outdoor units. (__) Coordinated to GE LV equipment _________ Includes copper flexible connectors. TEST REQUIREMENTS Each transformer shall receive all standard commercial tests in accordance with ANSI C57.12.90 (latest revision), with tests report available by serial number of the transformer. Routine tests include: -Resistance measurements of all windings -Ratio tests on the rated voltage connection and all tap connections -Polarity and phase relation tests on the rated voltage connection -No load loss at rated voltage -Exciting current at rated voltage -Impedance and load loss -Applied and Induced potential tests GE’s sales organizations and distributor network will provide technical sales and service for GE Prolec products as they do for all other GEJT&D products and systems. GE’s installation and service Engineers group, along with it’s network of Apparatus Service Centers strategically located throughout North America, provide the new joint venture with a service network second to none. All products manufactured under the JV will portray the GE monogram and carry the standard GE warranty. Look Come to Monterrey and Take a Closer Standards ANSI/IEEE NEMA, NOM (Mexico) BRINGING YOU QUALITY, TECHNOLOGY-BASED TRANSFORMER PRODUCTS... INDUSTRIAL TRANSFORMERS Phone: 1-800-GEPROLEC Fax: 011 528 156 2201 US Contact (706) 291 3384 (706) 291 3144 GE Dial Com 8 292-3384 8 292-3144 Or contact your local GE Sales Representative for more information.