No. SS1405 TECHNICAL SPECIFICATION IEEE C57.12.10 . I. EEE Standard Requirements for Liquid...

TECHNICAL

SPECIFICATION

No. SS1405 ToC

REV 10

DATE: 07/17

CATEGORY

TRANSFORMERS/ REGULATORS SUBJECT

POWER TRANSFORMER, 116/12.47 kV

TABLE OF CONTENTS

1. PURPOSE....................................................................................................................................................... 1

2. DEFINITIONS ................................................................................................................................................. 1

3. SCOPE ........................................................................................................................................................... 1

4. REFERENCES .................................................................................................................................................. 3

5. SERVICE CONDITIONS ................................................................................................................................... 7

6. CONSTRUCTION ............................................................................................................................................ 8

7. RATINGS ....................................................................................................................................................... 8

8. TRANSPORTATION & HANDLING REQUIREMENTS ........................................................................................ 9

9. STRUCTURAL DESIGN .................................................................................................................................. 10

10. SEISMIC REQUIREMENTS ............................................................................................................................ 11

11. ANCHORAGE APPENDAGES ......................................................................................................................... 11

12. DESIGN REVIEW .......................................................................................................................................... 12

13. TANK, BASE AND ACCESSORIES ................................................................................................................... 12

14. JACKING PADS AND LIFTING TRUNNIONS ................................................................................................... 13

15. TANK COVER ............................................................................................................................................... 15

16. FLANGES, GASKETS AND MANHOLES .......................................................................................................... 15

17. GROUNDING PADS ...................................................................................................................................... 16

18. TANK AND BASE MATERIALS ....................................................................................................................... 16

19. WELDING .................................................................................................................................................... 17

20. CONNECTION MATERIALS ........................................................................................................................... 18

21. PAINTING/COLOR ....................................................................................................................................... 19

22. FALL PROTECTION ....................................................................................................................................... 19

23. CORE AND COILS ......................................................................................................................................... 20

24. CURRENT TRANSFORMERS ......................................................................................................................... 24

25. BUSHINGS ................................................................................................................................................... 25

26. SURGE ARRESTERS ...................................................................................................................................... 27

27. LOAD TAP CHANGER (LTC) EQUIPMENT ...................................................................................................... 28

TECHNICAL

SPECIFICATION

No. SS1405 ToC

REV 10

DATE: 07/17

CATEGORY

TRANSFORMERS/ REGULATORS SUBJECT

POWER TRANSFORMER, 116/12.47 kV 28. ACCESSORIES AND CONTROL DEVICES ........................................................................................................ 31

29. CONTROL POWER ....................................................................................................................................... 35

30. SMUD CABLES, WIRING AND LABELING ...................................................................................................... 36

31. COOLING SYSTEM ....................................................................................................................................... 37

32. OIL PRESERVATION SYSTEM ........................................................................................................................ 38

33. TRANSFORMER OIL ..................................................................................................................................... 42

34. SOUND LEVEL .............................................................................................................................................. 43

35. TESTING ...................................................................................................................................................... 43

36. PHOTOGRAPHS ........................................................................................................................................... 52

37. LOSS EVALUATION ...................................................................................................................................... 52

38. BID SUBMITTAL ........................................................................................................................................... 53

39. CONTRACT SUBMITTALS ............................................................................................................................. 55

40. INSTRUCTION BOOK REQUIREMENTS ......................................................................................................... 58

41. QUALITY ASSURANCE.................................................................................................................................. 59

42. INSPECTION AND HOLD POINTS .................................................................................................................. 60

43. PREPARATION FOR SHIPMENT .................................................................................................................... 60

44. SHIPMENT AND DELIVERY ........................................................................................................................... 61

45. FIELD SERVICES ........................................................................................................................................... 63

46. ATTACHMENTS ........................................................................................................................................... 64

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1. PURPOSE

This specification has been developed to procure 116/12.47 kV, oil-filled, power 1.1transformers. The specification provides detailed requirements for the power transformer including design, documentation, furnishing, manufacturing, transporting, delivery, off-loading, on-site assembly, oil processing and testing.

This specification and all attachments are intended to inform the Contractor of 1.2technical requirements, design parameters, documentation requirements and evaluation criteria that must be incorporated into the design, manufacturing, performance, documentation, delivery, assembly and testing of the transformers.

2. DEFINITIONS

SMUD (Sacramento Municipal Utility District) - The purchaser and end user of the 2.1power transformers.

Contractor – The provider/bidder/manufacturer of the power transformers. 2.2

3. SCOPE

The transformer shall consist of three-phase, step-down power transformer with 3.1automatic load tap changer designed to supply a three-phase, four wire, grounded wye distribution system.

This Contractor shall be responsible for all shipping, drayage, and placing each 3.2transformer on SMUD’s designated foundation pad located in Sacramento County, California.

The Contractor shall also be responsible for onsite assembly, oil processing & filling, 3.3and testing the transformer after delivery.

The power transformer shall be complete with all accessories for installation, 3.4connection and immediate service.

All brackets, adapters, threaded fasteners, and other hardware necessary for complete 3.5field assembly of the transformer and accessory equipment shall be supplied.

All supplied materials shall be itemized on a complete bill of material. 3.6

The successful Contractor shall be responsible for providing a comprehensive 3.7structural engineering report for the transformer. The report shall include detailed

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design calculations, drawings, material information, quality control documentation, fabrication/assembly procedures and testing information.

The Contractor shall not begin the fabrication or assembly of the transformer prior to 3.8SMUD’s design review and the final approval of the transformer drawings, bill of material, nameplates and structural engineering report.

Work to be performed by SMUD: 3.9

3.9.1. Evaluate the qualified proposals. The transformer proposals will be evaluated by SMUD to determine the best qualified proposal and proposed transformer (considering initial cost of the transformer, cost of no-load and load losses, and costs of auxiliary losses). The Contractor’s proposal shall include all information and data requested in this specification. The Contractor submitting the proposal must provide documentation to substantiate the qualification requirements identified in section 3.11 - Contractor Qualifications.

3.9.2. Review and approval of submitted drawings, information, data, engineering reports, schedule & certified test reports.

3.9.3. Witness testing at the factory.

3.9.4. Receipt inspection.

3.9.5. Review and approval of all acceptance tests performed at the site.

3.9.6. Provide transformer foundation with embedded steel anchor plates.

3.9.7. Weld the transformer base to the foundation anchor plates.

3.9.8. Energize and load the transformer.

Contractor Qualifications: 3.10(Supporting documentation to be submitted by the Contractor with the proposal)

3.10.1. The Contractor shall provide documentation of continuous power transformer design & manufacturing experience for at least 20 years.

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3.10.2. The Contractor shall confirm that at least 400 power transformers have

been successfully designed, manufactured, tested, delivered, offloaded, assembled and commissioned in the last 10 years.

3.10.3. The Contractor shall provide the quality assurance program & procedures that will be followed during the transformer design, manufacturing & testing process.

3.10.4. The Contractor shall furnish the contact information for any subcontractor that will be involved with the delivery, offloading, assembly & testing of the transformer.

3.10.5. The Contractor shall provide at least 5 references from electric utility companies located in the United States that have taken ownership of similar transformers in the last 5 years. The references will be contacted by SMUD as part of the transformer bid evaluation process.

3.10.6. The Contractor shall provide a complete set of transformer drawings & documentation with the bid for a similar transformer (HV & LV rated voltage, with LTC and 30MVA top rating) that has been designed, manufactured & delivered in the last year.

3.10.7. The Contractor shall provide a sample structural design calculation and structural analysis of a similar transformer. The structural analysis shall include jacking, lifting and rolling parameters used for the transformer design.

3.10.8. The Contractor shall provide a sample seismic analysis report in accordance with IEEE 693 for a similar transformer.

4. REFERENCES

All equipment shall be designed, manufactured, tested, and supplied in accordance 4.1with the latest revision of the following codes and standards:

4.1.1. National Electric Manufacturers Association (NEMA)

4.1.2. American National Standards Institute (ANSI)

4.1.3. American Society for Testing and Materials (ASTM)

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4.1.4. Institute for Electrical and Electronic Engineers (IEEE)

4.1.5. American Institute of Steel Construction (AISC)

4.1.6. California Building Code (CBC)

4.1.7. American Society of Civil Engineers (ASCE)

4.1.8. American Welding Society (AWS)

4.1.9. The transformer shall be designed and manufactured in accordance with the latest revision of the following codes and standards:

IEEE C57.12.00 Standard General Requirements for Liquid-Immersed Distribution, Power, and Regulating Transformers.

IEEE C57.12.10 IEEE Standard Requirements for Liquid-Immersed Power Transformer

IEEE C57.12.70 Terminal Markings and Connections for Distribution and Power Transformers.

IEEE C57.12.80 Standard Terminology for Power and Distribution Transformers.

IEEE C57.12.90 Test Code for Liquid-Immersed Distribution, Power, and Regulating Transformers and Guide for Short-Circuit Testing of Distribution and Power Transformers.

IEEE C57.93 IEEE Guide for Installation and Maintenance of Oil-Immersed Power Transformers

IEEE C57.13 Standard Requirements for Instrument Transformers.

IEEE C57.13.1 Guide for Field Testing of Relaying Current Transformers

IEEE C57.13.2 Standard Conformance Test Procedures for Instrument Transformers

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IEEE C57.13.3 Guide for the Grounding of Instrument Transformer

Secondary Circuits and Cases

IEEE C57.19.00 General Requirements and Test Procedures for Outdoor Apparatus Bushings

IEEE C57.19.01 Standard Performance Characteristics and Dimensions for Outdoor Apparatus Bushings

IEEE C57.19.100 Guide for Application of Power Apparatus Bushings

IEEE C57.91 Guide for loading Mineral-oil-immersed Transformer

IEEE C57.98 Guide for Transformer Impulse Tests.

IEEE C57.106 Guide for Acceptance and Maintenance of Insulating Oil in Equipment

IEEE C57.109 Guide for Transformer Through-Fault-Current Duration.

IEEE C57.113 Guide for Partial Discharge Measurement in Liquid-Filled Power Transformers and Shunt Reactors.

IEEE C57.120 IEEE Loss Evaluation Guide for Power Transformers and Reactors

IEEE C57.131 IEEE Standard Requirements for Load Tap Changers

IEEE C57.150 IEEE Guide for the Transportation of Transformers and Reactors Rated 10 000 kVA or Higher

IEEE C62.11 Standard for Metal-Oxide Surge Arresters for AC Power Circuits.

ANSI C63.2 Standard for Instrumentation, Electromagnetic Noise & Field Strength

ANSI C84.1 Standard for Electric Power Systems and Equipment - Voltage Ratings (60 Hertz)

ANSI Z359.1 Safety Requirements for Personal Fall Arrest Systems.

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ASTM D117 Standard Guide to Test Methods and Specifications

for Electrical Insulating Oils of Petroleum Origin

ASTM D877 Standard Test Methods for Dielectric Breakdown Voltage of Insulating Liquids Using Disk Electrodes

ASTM D923 Standard Test Methods for Sampling Electrical Insulating Liquids

ASTM D1533 Standard Test Methods for Water in Insulating Liquids (Karl Fischer Method)

ASTM D1816 Standard Test Method for Dielectric Breakdown Voltage of Insulating Oils of Petroleum Origin Using VDE Electrodes

ASTM D3487 Standard Specification for Mineral Insulating Oil Used in Electrical Apparatus.

ASTM D4059 Analysis of Polychlorinated Biphenyls in Insulating Liquids by Gas Chromatography Method

IEEE 4 Standard Techniques for High-Voltage Testing

IEEE 693 Recommended Practice for Seismic Design of Substations.

IEEE 1527 Recommended Practice for the Design of Flexible Busywork Located in Seismically Active Areas

IEEE 1313.2 Guide for the Application of Insulation Coordination

IEEE 1538 Guide for Determination of Maximum Winding Temperature Rise in Liquid-Filled Transformers

NEMA LA1 Surge Arresters.

CBC California Building Code.

ASCE 7 Minimum Design Loads for Buildings and Other Structures.

ASCE 113 Substation Structure Design Guide

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ASTM A325 Specification for Structural Bolts, Steel, Heat Treated,

120/105 ksi Minimum Tensile Strength

AISC Steel Construction Manual (American Institute of Steel Construction)

AISC Research Council on Structural Connections, Specification for Structural Joints Using High Strength Bolts (Reference Included in the AISC Steel Construction Manual Listed Above)

AWS A2.4 Standard Symbols for Welding, Brazing, and Non-Destructive Examination

AWS A3.0 Standard Welding Terms and Definitions

AWS D1.1 Structural Welding Code-Steel

AWS D1.2 Structural Welding Code-Aluminum

AWS D1.6 Structural Welding Code-Stainless Steel

The Contractor shall notify SMUD and request clarification if conflicts between the 4.2referenced standards and this specification are discovered.

5. SERVICE CONDITIONS

Service Conditions shall be in accordance with the latest revision of IEEE C57.12.00. 5.1The transformers will be subjected to the atmospheric conditions of fog, rain, lightning, 100% relative humidity, wind, dust storms, and air temperature ranging from -10˚C to +50˚C. The 24 hour average temperature of cooling air is 40˚C.

The design wind pressure shall be in accordance with the latest edition of the 5.2California Building Code, except that the design wind pressure shall not be less than 36 psf. The Basic Wind Speed (V) shall be 90mph. The importance factor (I) shall be 1.15. The value for the height and exposure adjustment coefficient shall be 1.21. Exposure C shall be used. The design wind pressure shall not be reduced due to shielding if the component being designed is located behind another component. The design wind pressure shall be considered to originate from any direction and shall be applied across the total projected surface area of the component.

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Ancillary components shall not limit the transformer rating to less than the capability 5.3

of the windings.

6. CONSTRUCTION

The transformer shall be capable of withstanding, without damage, the thermal and 6.1mechanical stress caused by short circuit currents limited only by the impedance of the transformer.

System impedance shall be considered equal to zero and X0/X1 shall be equal to 2.0. 6.2System pre-fault voltage shall be equal to the voltage rating of the maximum tap.

All materials and accessories used in the manufacture of the transformer shall be new 6.3and unused.

Shielding on tank walls and frames shall be designed to mitigate gassing at 130% 6.4transformer overload.

7. RATINGS

The transformer shall be three phase, 60Hz, oil immersed, rated to supply 7.118000/24000/30000 kVA when supplied from the 116kV (HV) side to the 12.47kV (LV) side continuously with a 40°C average and 50°C maximum ambient temperature. The winding temperature rise at unity power factor and at power factor to 0.9 leading and 0.9 lagging shall not exceed the 55°C limit.

The power transformer & components including the bushings shall be capable of 7.2overload operation in accordance with the IEEE Standard C57.91 without greater loss of life than indicated in the guide.

The power transformer shall be capable of parallel operation with other transformers. 7.3

The power transformers shall be rated as follows: 7.4

7.4.1. Cooling Class Designation: ONAN/ONAF/ONAF

7.4.2. Frequency: 60Hz

7.4.3. Phase: Three (3)

7.4.4. Rated kVA (HV & LV) 18000/24000/30000 kVA

Voltage Rating, Taps & Connections: 7.5

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7.5.1. The (HV) windings shall be connected wye, with a voltage rating of

116,000 volts.

7.5.2. The (LV) windings shall be connected wye through a load tap changer for 12470 volts, four-wire grounded neutral service.

7.5.3. The buried tertiary windings shall be connected delta with a voltage rating determined by the Contractor. Buried tertiary KVA rating shall be (HV) winding KVA times 35% or greater, as required for supplying the transformer’s neutral stabilization and harmonic suppression requirements.

The transformer impedance shall be nominal 13.0 percent, plus/minus 7.5 percent 7.6tolerance, 116 to 12.47 kV at the ONAN rating. The transformer impedance requirement is intended to limit SMUD’s 12.47kV distribution network available fault current to 25,000 amps.

The de-energized tap changer shall be rated 116kV ± 5% with two steps above and 7.7two steps below nominal. The de-energized tap changer shall be capable of delivering the transformer rated kVA at all taps. All tap positions and connections shall be designed to withstand the same operating and short circuit conditions as the transformer winding. The de-energized tap changer shall be manually operated and include provisions for padlocking. An operating handle with a positive position indicator shall be located a maximum of 60 inches above the base of the transformer. The de-energized tap changer mechanism shall be designed to provide simultaneous operation of all three phases and not leave a winding open or short-circuited when the operating handle is placed in a locked position. The de-energized tap changer shall not require periodic operation or maintenance. The contacts of the de-energized tap changer shall be silver-plated. The de-energized tap changer mechanism inside the tank shall be accessible through convenient access ports.

The temperature of non-insulated parts shall not exceed 130°C. 7.8

8. TRANSPORTATION & HANDLING REQUIREMENTS

The transformers shall be designed for the governing load combinations of handling 8.1(lifting, jacking, rolling/skidding, positioning), and transportation loads.

The transformers shall be designed to be fully assembled and filled with oil during 8.2handling (lifting, jacking, rolling/skidding, positioning).

The transformers & any separately shipped components shall be designed to withstand 8.3transportation conditions (physical impacts) to insure delivery/receipt at the substation site without internal or external damage of any kind. The modes of transportation

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include, but are not limited to, transportation by ship, rail (including the U.S. rail system) and truck. The minimum design accelerations shall be as follows:

8.3.1. Longitudinal: 5g

8.3.2. Vertical: 3g

8.3.3. Transverse: 2g

The Contractor shall design for greater values if required by the mode of transportation 8.4or transportation equipment used.

The Contractor shall provide SMUD with complete calculations that clearly indicate 8.5the allowable design accelerations. SMUD will compare these values to the actual accelerations logged by the impact recorders to verify the transformer was not subjected to adverse handling during shipment and delivery.

9. STRUCTURAL DESIGN

The transformer, including all internal and external accessories and appendages, shall 9.1be designed for the governing load combinations of wind, seismic, handling (lifting, jacking, rolling/skidding, positioning), transportation, and operation loads.

The transformer internal components, external accessories and appendages shall be 9.2designed to mitigate structural damage and/or loss of function during and after an earthquake when subjected to design seismic loads occurring simultaneously with dead and normal operation loads.

All lifting eyes, plates, or similar attachments used for rigging/lifting of transformer 9.3components or appendages shall be designed with a minimum safety factor of 5:1 per IEEE ANSI C57.12.10.

The Contractor shall provide a detailed structural design report for the transformer that 9.4has been certified by a licensed California Professional Structural Engineer. The report shall include but not be limited to:

9.4.1. Structural calculations for all positioning (lifting, jacking, rolling/skidding, positioning) components, in accordance with IEEE ANSI C57.12.10. Lifting and jacking appurtenances shall be designed with a safety factor of 5:1. The safety factor for lifting and jacking appurtenances shall be verified in the structural design calculations. Pulling appurtenances shall be designed with a safety factor of 3:1. The safety factor for pulling appurtenances shall be verified in the structural design calculations.

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9.4.2. Structural calculations shall include transformer tank design, cover,

radiator supports, cabinet supports and all other components that are structurally supported on the transformer.

9.4.3. Detailed drawings and structural calculations in accordance with this specification and any applicable codes, standards, references, and SMUD’s TECHNICAL SPECIFICATION SS1407 - TRANSFORMER STRUCTURAL DESIGN REVIEW SUBMITTAL GUIDE (attachment to this specification).

10. SEISMIC REQUIREMENTS

The transformer seismic design shall be qualified to the requirements set forth in the 10.1latest edition of IEEE Standard 693, Annex S, Annex T.

The transformer shall meet the requirements for the “high seismic” qualification level 10.2at 115kV. The report shall be reviewed, stamped, signed, and dated by a currently licensed California Professional Civil or Structural Engineer with demonstrated experience in seismic design of transformers.

Frequency modifying devices are not acceptable. 10.3

The transformer will be located on a SMUD supplied concrete foundation with 10.4embedded steel anchor plates. The transformer base will be welded to the anchor plates and the anchorage connection shall be designed by the Contractor to meet the seismic requirements. The pad type foundation shall be considered flat and rigid.

11. ANCHORAGE APPENDAGES

The Contractor shall design and provide anchorage appendages on the transformer 11.1base for welding the transformer to the anchor plates embedded in the foundation.

The transformer anchorage shall be designed to meet the controlling load 11.2combinations and all seismic design requirements.

The number and location of anchorage appendages shall be as designed by the 11.3Contractor for the governing load combinations and the load path. The Contractor shall provide recommendations & requirements for the welded connection of the anchorage appendages to the embedded anchor plates.

All weld requirements shall conform to applicable AWS specifications. 11.4

The anchorage appendages shall be symmetrically located on the transformer base. 11.5

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The transformer appendages shall be designed to withstand vertical forces that can be 11.6

experienced during a seismic event.

Transformer anchorage appendages shall lie flat and in contact with the embedded 11.7anchor plates.

The transformer anchorage drawings shown on the seismic outline drawing(s) and 11.8calculations shall be provided in the transformer structural report.

The transformer anchor loads shall be based upon IEEE Standard 693, high seismic 11.9level, considering the rotation caused by the center of gravity location.

The Contractor shall provide calculations or other means to document the location of 11.10the center of gravity (x, y, and z axis).

Frictional resistance between the transformer base and concrete shall not be considered 11.11in the anchorage appendage design.

12. DESIGN REVIEW

The Contractor shall provide SMUD all requested data, calculations, drawings, 12.1procedures, and other information necessary for a comprehensive electrical, thermal, mechanical and structural design review. The Contractor shall have the design team available for discussion of the results of the design review. Manufacturing of the transformer shall not proceed until the Contractor has received final design approval from SMUD. SMUD reserves the right to perform a detailed independent review of the Contractor’s transformer design. The design review includes information described in SMUD’s TECHNICAL SPECIFICATION SS1406 - ELECTRICAL DESIGN REVIEW CHECK LIST (attachment to this specification).

13. TANK, BASE AND ACCESSORIES

Tanks, bases, radiators, covers, junction boxes, control cabinets and all internal 13.1components shall withstand normal transportation, installation, and service stresses without distortion or damage.

The transformer base shall be designed with a maximum deflection of 0.25 inches (6 13.2mm) or less during transportation or handling with the transformer completely assembled and filled with oil.

The transformer base (in contact with the concrete foundation) shall be constructed 13.3using continuous heavy steel plate and/or constructed using heavy, continuous, enclosed rectangular structural steel tubing. The base plate thickness or tubing wall

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thickness in contact with the concrete surface shall be a minimum of 0.25 inches greater thickness than the minimum thickness required by design.

The structural steel plate and tubing on the transformer base shall be continuous. All 13.4segments of the plate and tubing shall be joined using complete penetration welding. All open tube ends shall be capped with a plate of a thickness equal to or greater than the tubing wall thickness.

The transformer base shall be completely sealed from moisture intrusion and designed 13.5for water shedding. There shall be no openings or pockets that could hold or trap water beneath the transformer.

All steel plate and shape intersections shall be completely welded with no open seams. 13.6

The base shall be constructed so that the external edges on all four sides are rounded 13.7or sloped upward at an angle of 45 degrees in accordance with IEEE C57.12.

The transformer tank, base and structural detail drawings including associated 13.8calculations shall be reviewed, stamped and signed by a currently licensed California Professional Civil or Structural Engineer. All drawings and calculations shall be submitted to SMUD for approval as part of the structural design submittals.

14. JACKING PADS AND LIFTING TRUNNIONS

Jacking pads and lifting trunnions shall be provided for lifting the transformer either 14.1by crane or by jacks when completely assembled and filled with oil.

Jacking pads shall be provided on all four corners of the tank near the base area. The 14.2jacking pads shall be designed to accommodate a cylinder type hydraulic jack with unobstructed clearance between the concrete foundation and the jacking pad plate of 19.5 inches (500 mm) and a minimum of 9 inches (230 mm) width unobstructed clearance beyond the transformer. The jacking pads shall be designed to accommodate shackles for transportation tie-downs and pulling in any direction during installation skidding operations.

Lifting trunnions shall be provided on all four corners of the upper tank area. The 14.3upper lifting trunnions shall be designed to accommodate either wire rope slings or synthetic slings. The four upper lifting trunnions and tank shall be designed to support four slings attached to a single lifting point above the transformer (crane hook block or similar) above the transformer. The lifting trunnion design shall not require the use of a spreader bar.

The transformer jacking pad locations shall be designed to jack the transformer when 14.4completely assembled and filled with oil with a minimum safety factor of 5:1 of the

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ultimate structural strength of the controlling elements within the load path, per IEEE C57.12.10, or more stringent design requirements if required by the referenced design standards or transformer manufacturer. The design load used for analysis shall be the maximum load based upon the weight and center of gravity location when the transformer is completely assembled and filled with oil while supported on four points.

The transformer lifting trunnion & jacking pad locations shall be capable of safely 14.5supporting the entire weight of the transformer on two opposite lifting points (incidental cross corner loading) when the transformer is completely assembled and filled with oil without exceeding allowable material stresses of the controlling elements within the load path (load application area, local material stresses, overall tank stresses, and all other components along the path required to support the load), visible distortion, or damage.

The design load used for analysis shall be the maximum load based upon the weight 14.6and center of gravity location when the transformer is fully assembled and filled with oil while being supported on two opposite load points.

The pulling facilities (horizontal pulling for skidding only) shall be designed with a 14.7minimum safety factor of 3:1 of the ultimate structural strength of the controlling elements within the load path (load application area, local material stresses, overall tank stresses, and all other components along the load path required to support the load).

The coefficient of static friction for determining the pulling loads shall not be less than 14.80.30 (30% of the total transformer weight when fully assembled and filled with oil) applied to a maximum of two pulling points on one side of the transformer.

The rigging angle used for calculations at the pulling points shall have a minimum 14.9range of 0 degrees to 90 degrees in either direction.

Provisions shall be made for lifting the core and coil assembly from the tank per IEEE 14.10C57.12.10, Section 5.3.2. Guides shall be provided within the tank for guiding the core coil assembly during placement in or removal from the tank.

The transformer jacking and lifting detail drawings including associated calculations 14.11shall be reviewed, stamped and signed by a currently licensed California Professional Civil or Structural Engineer. All drawings and calculations shall be submitted to SMUD for approval as part of the structural design submittals. The drawings & calculations shall indicate the following information:

14.11.1. Load application point (for lifting, jacking, and rolling) and maximum capacity of load application point.

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14.11.2. Plan, front and side view elevations of the fully assembled transformer

with lifting slings depicted shall be provided including sling lengths, sling angle limitations, transformer center of gravity and transformer weight.

14.11.3. Drawings shall indicate jacking locations and maximum jack height dimensions.

14.11.4. Drawings shall include roller placement and pulling locations.

15. TANK COVER

The tank cover shall be sloped or domed to shed water and shall be welded at the 15.1factory. Bolted covers are not acceptable.

The transformer top cover shall include textured slip-resistant surface and the mast 15.2mounting plate for SMUD’s personnel fall protection system (see drawing SDS-S3C-A002 attachment to this specification).

The tank cover shall be designed with a manhole access for removal of current 15.3transformers.

Transformer tank and fittings shall be of welded steel construction and shall withstand 15.4without leakage or distortion, a pressure 25 percent greater than the maximum operating pressures (positive and negative) resulting from the oil preservation system used.

Transformer cover lifting provisions shall be included. Covers shall be welded to the 15.5tank in a manner that will facilitate removal when necessary. A suitable gasket or other means shall be provided for the internal opening to prevent weld splatter from entering the tank.

The cover and sidewall thicknesses, with or without reinforcing, and with or without 15.6supporting booms, shall be designed to minimize seismic forces amplification to arrestors and bushings beyond their approved moderate seismic qualification level.

The seismic analysis shall include all of the various appurtenances motion effect 15.7during a seismic event.

16. FLANGES, GASKETS AND MANHOLES

All flanged and gasketed oil-tight joints shall be provided with one-piece gaskets set in 16.1grooves or held in position by stops to prevent over compression and spreading of gaskets.

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The gaskets shall be made of resilient material that will not deteriorate in the presence 16.2

of hot oil. Any joints below oil level shall be completely welded, except for radiator connections and manholes. All gasketed joints on the top of the cover shall utilize flanges which are raised at least 0.75 inches above the cover.

Unconfined gasketed joints shall be designed to mitigate un-equal structural forces 16.3(joint bending) applied. Unconfined gasketed joints shall not structurally support appurtenances.

Two 20 inch diameter transformer manholes shall be located on the cover and shall 16.4provide easy access to the lower ends of the bushings, terminals, LTC leads, upper portion of coils, and to permit replacement of bushing current transformers. Manhole covers shall bolted to the transformer tank and include lifting handles.

Raised-machined grooved flanges shall be provided for bushings, manholes and 16.5accessories requiring flanges to prevent moisture or debris from entering the transformer when bushings, manhole and accessory covers are removed.

Flanged valves and terminals shall be furnished with blank flanges for shipping. Screw 16.6type valves shall be furnished with brass screw plugs. All valves used in the insulating oil system shall be brass or bronze.

An extra set of flanged valves shall be provided for the future addition of a radiator. 16.7

17. GROUNDING PADS

Stainless Steel faced grounding pads (NEMA 2 hole) shall be provided at all four (4) 17.1corners of the tank base.

A removable connection to the transformer H0 & X0 neutral bushings shall be 17.2insulated from the transformer and connected to the transformer ground pads.

18. TANK AND BASE MATERIALS

All steel materials for the tank and base construction shall be provided with Material 18.1Test Reports (MTR’s), which meet the Contractor’s design requirements described on the design drawings and calculations.

The MTR’s shall provide the chemical composition of the steel material and physical 18.2properties including yield stress, and tensile stress.

The heat numbers on the MTR’s shall match the heat numbers on the material 18.3provided.

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The MTR’s shall be made available to SMUD upon request and shall be provided with 18.4

the final transformer submittals.

19. WELDING

All transformer tank seams shall be complete penetration welded from both sides of 19.1the seam using a double bevel, v-groove type weld or SMUD approved equal. The welds shall be a minimum of twelve inches from the corners of the tank. Corner welds are not acceptable.

Contractor shall provide standard tank connections and welding procedures prior to 19.2fabrication for approval by SMUD.

All weld backing plates, if required for the weld type used, shall be removed. 19.3

Weld over-runs shall be removed and ground smooth. Any access slots or holes 19.4required for welding access shall be filled after use and ground flush.

All welding shall meet or exceed all of the requirements set forth in the latest edition 19.5of AWS D1.1 for the material and process used.

All welders shall have current welding certification in accordance with AWS D1.1 for 19.6the equipment, material and process used.

All welds shall be non-destructively tested (NDT) and inspected by a certified 19.7inspector in accordance with AWS D1.1.

The weld inspection shall meet or exceed the following requirements: 19.8

19.8.1. All partial and complete penetration welds shall be 100% ultrasonically inspected (UT).

19.8.2. All fillet welds shall be 100% visually inspected (VT) and a minimum of 20% of the fillet welds (randomly sampled throughout the structures) shall be magnetic particle inspected (MT) (or greater % if required by the Contractor).

19.8.3. All fillet welds used for the lifting, jacking, and pulling facilities up to and including any welds to the tank wall shall be 100% VT and MT inspected.

The Contractor shall maintain records of all weld testing. The records shall include a 19.9minimum of the following:

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19.9.1. Weld location (provided on a weld map of the structure).

19.9.2. Weld type.

19.9.3. Material type & Material thickness.

19.9.4. Weld test used.

19.9.5. Test date, weld inspector.

19.9.6. Weld inspector certificates.

19.9.7. Test results.

19.9.8. The weld test reports shall be made available to SMUD upon request and shall be provided with the final transformer structural report.

20. CONNECTION MATERIALS

All nuts, bolts, studs and screws shall conform to the ANSI standards of pitch, thread 20.1shapes, dimensions, and tolerances. Metric nuts, bolts, studs and screws are not acceptable.

All bolts used for structural purposes and using standard holes (bolt diameter +1/16”) 20.2shall conform to ASTM A325. All washers shall conform to ASTM F436.

All nuts shall conform to ASTM A194 2H. 20.3

All bolts, nuts, and washers shall be hot-dip galvanized in accordance with ASTM 20.4A153.

All bolts used for structural purposes using oversized and slotted holes shall conform 20.5to ASTM A325SC (slip critical requiring pre-tensioning).

All washers shall conform to ASTM F436. All nuts shall conform to ASTM A194 2H. 20.6All bolts, nuts, and washers shall be hot-dip galvanized in accordance with ASTM A153.

Bolt installation and tensioning shall be per the AISC Steel Construction Manual 20.7(Research Council on Structural Connections-- Specification for Structural Joints Using High Strength Bolts). Split or lock washers are not acceptable.

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All bolt minimum edge distances shall be in accordance with the AISC Steel 20.8

Construction Manual. Greater edge distances shall be used if required by calculations.

All hole spacing shall be in accordance with the AISC Steel Construction Manual. 20.9

Drilled and tapped holes (threaded into plate) shall not be used for bolted structural 20.10connections.

The Contractor shall provide detailed calculations and special installation instructions 20.11of screws that resist seismic forces, particularly high-strength screws installed into lower yield material.

21. PAINTING/COLOR

All external porcelain shall be ANSI # 70 light gray color (Munsell No. 5BG 7.0/0.4) 21.1or SMUD approved equal.

All exposed metal surfaces, excluding terminals, conductors and fans, shall be painted 21.2ANSI gray color # 61, or SMUD approved equal.

The finish coat shall be suitable for painting over in the field with no preparation other 21.3than cleaning.

A minimum of one gallon each of touch-up primer and finish paint shall be provided 21.4for each transformer.

All paint finishes shall meet ANSI C57.12.28, section 5. Vinyl based paint is not 21.5acceptable.

The inside of the transformer tank, LTC tank, air terminal chamber and main control 21.6cabinet shall be painted white.

22. FALL PROTECTION

The transformer shall be provided with a mast mounting plate for SMUD’s personnel 22.1fall protection system (see drawing SDS-S3C-A002 attachment to this specification).

A single mast mounting plate shall be located at the approximate center of the tank 22.2cover for transformers less than sixteen feet of overall length, including attachments. Two mast mounting plates shall be attached to the tank cover at 1/3 intervals along the centerline of the transformer for transformers exceeding sixteen feet of overall length, including attachments.

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Mounting plates shall conform to ANSI Z359.1 standards, and CAL-OSHA 22.3

regulations for fall arrest systems. Mounting plates shall have adequate strength to support a 5000 lb. maximum load applied in any direction to the top of a SMUD-furnished pole attached to the plate.

23. CORE AND COILS

Transformer cores shall be constructed of high grade, non-aging, grain-oriented, laser 23.1scribed thin electrical silicon steel of low hysteresis and low eddy current losses with high permeability. Core saturation flux density at 115% of rated voltage shall be below the knee of the core saturation curve to avoid core saturation. The core shall be stacked, with mitered step lap joint construction and full length top yoke.

The Contractor shall provide a detailed core and coil structural analysis, which 23.2addresses the adequacy of all core/coil connections to the base, sidewalls, end walls, and cover if utilized. The core and coil structural analysis shall include all structural bracing and the core clamping beams. All possible loads and load combinations shall be evaluated in the analysis. A detailed report including of core and coil design and construction shall be provided by the Contractor. The details shall include bolting, welding, blocking and anchorage material.

The maximum acceptable burr on the cut edges of the core steel is 0.02 mm (0.008 23.3inches).

Nuts, bolts, and clamps of the core assembly shall be provided with positive locking 23.4devices to prevent loosening or slippage.

The complete core and coil assembly shall be removable from the tank. 23.5

Lifting eyes or lugs shall be provided for lifting the core and coils. All lifting 23.6appurtenances shall be part of the structural report.

Bolts through the core are not acceptable. 23.7

The core shall be securely grounded to the tank through an external bushing. The core 23.8ground bushing shall be a Central Moloney part number 70131551 or SMUD approved equal, to provide a detachable connection made in an externally located terminal box with gasketed cover, accessible without requiring entry into the main tank. A separate core ground bushing shall be provided for the preventive autotransformer.

The windings of the transformer shall have the following insulation requirements: 23.9

23.9.1. 116 kV line terminals - 450kV BIL

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23.9.2. 12.47 kV line terminals - 110kV BIL

23.9.3. Neutral terminals - 110kV BIL

The windings shall be capable of withstanding all impulse and dielectric tests specified 23.10in these specifications.

The conductors and insulation shall be designed to mitigate the formation of partial 23.11discharges, not only at the operating voltage, but also during the dielectric tests.

Winding conductor material shall be electrolytic copper of high quality. The 23.12conductors shall be designed to assure mechanical strength and to minimize electrostatic flux concentration. Individual conductors of the (HV) and (LV) windings shall be rectangular with rounded edges and enamel coated. Windings shall consist of multiple conductors (continuously transposed conductor - CTC) and epoxy bonded. The conductors shall be smooth and free of scale, burrs and foreign materials.

Winding leads shall be brought out on the same side of the winding to avoid half-turn 23.13offsets. Use of compensating turns directly wound on the core (external to the winding) is not acceptable. Tap leads shall be rigidly supported with pressboard clamps.

Joints in winding conductors shall be brazed or welded. Joints shall be properly 23.14formed and finished, and carefully insulated to conform to the basic insulation level. Crimped joints will not be accepted. Bolted or clamp type connections may be used at bushings, tap changers, and terminal boards provided that suitable locking devices are used to prevent loosening of connections.

Suitable cooling liquid passages shall be provided in windings/core to limit the hottest-23.15spot temperature rise.

Axial and/or radial insulating spacers at frequent intervals shall be permanently 23.16secured in place for cooling of windings. Spacers shall be arranged to assure positive and effective oil circulation all throughout the intended design life of the transformer. All insulating spacers shall be compressed at high pressure before installation in the windings.

There shall be no permanent deformation to the completed winding assembly by the 23.17stresses incident due to shipment or the required short circuits.

The insulating materials used shall be non-hygroscopic, insoluble in, and not acted 23.18upon by the transformer oil at operating temperatures. All varnish and other insulating materials used shall not be affected by ordinary petroleum distillates having flash points above 170°C.

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High density crepe paper, Dennison 22HCC or approved equal shall be used for all 23.19conductor taping. Paper insulating materials shall be thermally upgraded for a 65°C temperature rise rating.

All pressboard parts except formed parts shall be made from pre-compressed material 23.20having a minimum density of 1.15 gm/cc. The formed parts shall be made from pressboard having a minimum density of 0.9 gm/cc. The conductor insulation shall be of high quality, thermally stable, resistant to traction and flexibility.

The maximum dielectric stress between conductors at 100% operating voltage shall 23.21not exceed 2.65kV RMS per mm at any tap position.

The (LV) winding shall be designed to reduce the compensating current in the core 23.22and core clamps.

The electrical stresses in the insulation structure shall be limited to 80% of the 23.23Weidmann Curves for Partial Discharge Inception for Insulated Electrodes in Degassed Oil. The impulse ratio used to convert impulse voltages to power frequency voltages shall be no greater than 2.5. Oil gap and creep stresses on pressboard will be a design review item.

The assembled core and coils shall be impregnated and processed through a vapor 23.24phase drying system.

Moisture contained in the insulation system shall be reduced to 0.75% or less at the 23.25time of oil impregnation so that an insulation power factor of less than 0.35% shall be obtained.

Windings shall be either disk or helical construction. Barrel or sheet windings and 23.26rectangular core and coil designs are not acceptable.

Thermally upgraded paper insulation shall be wound onto the conductor employing a 23.27spinning process. The paper insulation shall be applied in single or multiple strands such that a minimum of 30% of the paper surfaces are overlapped.

All windings shall be copper. Continuously transposed conductor shall be epoxy 23.28bonded.

All windings shall be self-supporting for inward (buckling) and outward (hoop) forces. 23.29

Windings shall not rely on the core assembly for support to resist inward short-circuit 23.30forces.

Winding capability to resist inward radial forces shall be based on ability of conductor 23.31to resist forces in a "free-buckling" mode.

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The free buckling stresses in the conductor shall not exceed 65% of the 0.2% yield 23.32stress for the conductor.

Tensile stresses in all windings shall be limited to 80% of the 0.2% yield stress of the 23.33conductor material.

The tertiary winding shall be an integral part of the main core/windings. The 23.34Contractor shall provide the short circuit withstand capability of the tertiary winding.

The regulating voltage winding or coils used to change the voltage of the transformer 23.35shall be designed to mitigate the

The mechanical stresses in the regulating voltage portion of the winding are to be 23.36calculated and available during the design review.

The hot spot within the body of the core shall be limited to 130ºC. This temperature 23.37relates to an ambient temperature of 40ºC.

The limiting temperature applies to the worst-case condition of 100% voltage at full 23.38load, 105% voltage at full load, and 110% voltage at no-load. If the worst-case condition occurs with full load, the regulation shall be calculated with a 0.8 power factor.

The transformer shall be capable of withstanding, without damage, the mechanical and 23.39thermal stresses caused by external short circuits. The through-fault capacity shall be in accordance with IEEE C57.12.00, C57.12.90 and C57.109 on all tap positions. Short circuit calculations shall assume an infinite bus capacity.

The Contractor shall demonstrate that the transformer, including tertiary winding, 23.40meets the through-fault-current withstand capability by one of the following methods:

23.40.1. Certified test data showing that a transformer with a core and coil identical in design and construction and identical or similar with respect to MVA capacity, kV ratings, BIL, and voltage taps has been tested under maximum short-circuit conditions without failure. A description of the test code under which the transformer was tested for short-circuit strength shall be provided by the Contractor to SMUD.

23.40.2. A history of successful experience with transformers of identical or similar ratings, design and construction. The Contractor shall list all transformers in service with core and coils that are essentially identical in design and construction to the transformer covered by this specification and shall provide information on the date of installation, location, and failures, if any. Where such transformers have not been built or the cumulative

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service record is less than 20 transformer years, a list of transformers in service that represent the closest approximation to the transformer covered by this specification shall be submitted. The information submitted shall be the total experience of the Contractor for the design of the transformer to be furnished, including the dates of installation, (or shipment, if not installed), the ratings of the transformers, customer contacts, a list of failures, failure dates and causes of failures, if any, that have been experienced.

The core support structures shall be designed to prevent circulating currents in the core 23.41and mechanical support structure.

One piece top and bottom coil clamping rings are required. 23.42

All portions of the core shall be compressed and remain compressed for the service 23.43life of the transformer.

24. CURRENT TRANSFORMERS

All bushing current transformers shall have fully distributed windings for relaying 24.1service.

The current transformer Thermal Rating Factor (TRF) shall be at least 2.0. 24.2

All current transformers shall be multi-ratio with standard taps and shall have accuracy 24.3classifications not lower than those specified in IEEE C57.13.

All secondary leads from current transformers shall be terminated on short-circuiting 24.4type terminal blocks (GE type EB-27 or approved equal) mounted in the transformer control cabinet.

Current transformer leads shall be 10 AWG minimum stranded copper with SIS cross-24.5linked polyethylene insulation rated 90°C. CT wiring shall be installed with adequate supports & bracing to withstand the mechanical impacts during shipment & handling. Current transformer leads shall not be spliced.

Current transformer lead tank penetrations shall use a multi-stud type bulkhead 24.6pressure penetration feed-through using ring-tongue lugs with locking nuts. Pigtails with splices are not acceptable.

The current transformers shall be adequately supported to withstand short-circuit 24.7stresses within the transformer and shall have sufficient thermal capacity and mechanical strength to withstand the through-fault-current/duration criteria.

All current transformers shall be installed during all transformer tests. 24.8

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The following current transformers shall be furnished: 24.9

24.9.1. 116kV Bushings .........................Two per phase, 1200/5 Amps, C800

24.9.2. 12.47kV Bushings .......................Two per phase, 2000/5 Amps, C800

24.9.3. 116kV Neutral H0........................One, 1200/5 Amps, C800

24.9.4. 12.47 kV Neutral X0....................One, 2000/5 Amps, C800

24.9.5. Tertiary.........................................One, 1200/5 Amps, C800 within Delta

24.9.6. LTC & winding temperature........Contractor’s standard requirements

The Contractor shall furnish certified copies of the following current transformer 24.10application data:

24.10.1. Typical excitation curves for each turn ratio.

24.10.2. Typical ratio correction factor curves for each turn ratio.

24.10.3. Winding and lead resistance per turn.

25. BUSHINGS

Bushings shall be provided for the 116kV high voltage (HV) terminals, 12.47kV low 25.1voltage (LV) terminals, H0 and X0 terminals.

The 116 kV bushings shall be capacitance graded with paper-metal foil wrap 25.2condenser type design. Solid or composite bushing insulation is not acceptable.

The 116kV HV bushings shall be equipped with a capacitance tap suitable for 25.3providing a voltage supply for a potential device.

All bushings shall be removable and shall be draw lead type if possible. 25.4

Bushings shall meet the dimensional/test requirements of IEEE C57.19.00. 25.5

All oil-filled bushings shall have a sealed reservoir with an oil gauge and transparent 25.6window, for fill verification.

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All bushings shall be furnished with silver-plated external contact surface. Bushings 25.7

shall have threaded terminal studs.

All bushings shall be furnished with a NEMA four-hole pad terminal. 25.8

All bushings shall be constructed by using wet process porcelain materials with a 25.9homogeneous surface. Bushings shall be one-piece porcelain under compression only. The transformer drawings shall indicate the size, diameter, number of strands, and material of the bushing draw lead for draw lead type bushings.

Outline drawings of each bushing shall be included with the transformer approval 25.10drawings.

Instruction manuals for each style of bushing shall be included with the transformer 25.11instruction manuals.

Bushings shall be furnished with the following minimum requirements: 25.12

25.12.1. 116kV high voltage terminals – 550 kV BIL, 1200A.

25.12.2. 12.47 kV low voltage terminals – 110 kV BIL, 2000A

25.12.3. Neutral terminals – 110 kV BIL, 2000A

25.12.4. The bushings shall be sized to not limit the transformer rating.

The transformer bushings shall be manufactured by Pcore Electric Co. or ABB. 25.13

25.13.1. 116kV (HV) bushings: PCORE # POC550G1216RS

25.13.2. 12.47kV (LV & X0) bushings: ABB #015B0200BC

25.13.3. H0 bushing: PCORE #B88713-70 (25kV)

The location of the bushings shall be in the segments specified as referenced in 25.14Figure 1 of IEEE C57.12.10.

The 116 kV (HV) bushings shall be in segment location 3. 25.15

The 12.47 kV (LV & X0) bushings shall be side wall mounted beneath segment 25.16location 1 in the air terminal chamber.

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The air terminal chamber shall include a copper cable termination bus and removable 25.17link between the bushings and the bus. The cable termination bus shall be supported with insulators in the air terminal chamber. The cable termination bus shall be designed for the connection of four (4) underground power cables per phase with 4 hole NEMA pads. The air terminal chamber shall include structural power cable supports. The floor of the air terminal chamber shall include cover plates for termination of power conduits. A solid ground connection shall be provided from the X0 bushing to the ground bus located in the air terminal chamber. Access doors shall be provided on three sides of the air terminal chamber. See attachment drawing EDS-E2B-D006 OUTLINE & DETAIL TRANSFORMER AIR TERMINAL CHAMBER for additional information.

The H0 bushing shall be located by the Contractor and mounted on the transformer 25.18cover.

The minimum distance between the 116kV (HV) bushings shall be 53 inches. The 25.19minimum distance between 12.47 kV (LV) bushings shall be 20 inches.

The seismic analysis shall meet the requirements of both IEEE 693 and this 25.20specification:

25.20.1. Bushing supports shall be rigid and strong enough to minimize support deflection during a seismic event. Bushing supports shall be designed such that the seismic force amplification is not beyond the approved high seismic qualification level.

25.20.2. All information shall be fully documented and provided in the structural report. The information shall also include the maximum anticipated deflections of the bushings when mounted on the transformer.

26. SURGE ARRESTERS

Surge arrester protective characteristics shall coordinate with transformer insulation to 26.1give satisfactory protection to the transformer per IEEE C62.11, IEEE 1313.2, and NEMA LA1.

Each 116 kV surge arrester shall have a maximum continuous line-to-ground operating 26.2voltage (MCOV) of not less than 76 kV.

The 116 kV line terminals shall be provided with station class, metal oxide surge 26.3arresters in accordance with IEEE Standard C62.11.

The surge arresters shall be provided with NEMA standard connectors for securing 26.4copper or aluminum conductors between #2 and #4/0 AWG.

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Surge arresters shall be provided with full capacity copper connections between 26.5

arresters and transformer bushing terminals with provisions for expansion and contraction.

The surge arresters shall be vertically mounted on insulated bases above the 26.6transformer top cover elevation.

All necessary mounting brackets, hardware, and grounding conductors for the surge 26.7arresters shall be provided. The grounding conductors shall be either bare copper supported by stand-off insulators or insulated copper cable supported by cable clamps.

Surge arrestors and surge counters shall be appropriately insulated from the 26.8transformer tank.

Each 116 kV arrester shall have a surge counter to indicate operations and a leakage 26.9detector to indicate current leakage. The surge counter and current leakage detector shall be mounted to be visible from the ground.

The surge counter shall be by EMP Bowthorpe or SMUD approved equal. 26.10

Each arrester surge counter shall have a momentary contact, which closes during 26.11discharge of the arrester. The contact shall be wired to a terminal block in the transformer control cabinet for alarm connections.

The seismic analysis shall meet the requirements of both IEEE 693 and this 26.12specification:

26.12.1. Surge arrester supports shall be rigid and strong enough to minimize support deflection during a seismic event. Arrester supports shall be designed such that the seismic force amplification is not beyond the approved high seismic qualification level.

26.12.2. All information shall be fully documented and provided in the structural report. The information shall also include the maximum anticipated deflections of the arresters when mounted on the transformer.

27. LOAD TAP CHANGER (LTC) EQUIPMENT

The 12.47kV (LV) voltage LTC shall be a Reinhausen Manufacturing Inc., 27.1VACUTAP® RMV-II with model “B” monitoring system and motor drive unit TAPMOTION MD-III (Reinhausen/SMUD standard project# 4647967). The LTC shall be rated 15 kV, 1500A.

Load tap changing equipment shall be provided as described in IEEE C57.12.10. 27.2

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The equipment for automatic tap changing under load shall provide plus and minus 10 27.3

percent voltage regulation in sixteen full capacity 5/8 percent steps above and sixteen reduced capacity 5/8 percent steps below rated 12.47kV (LV) output voltage.

The LTC compartment shall include the following: 27.4

27.4.1. Drain valve with sampling device.

27.4.2. Fill valve.

27.4.3. Dial-type oil level gauge with low-level alarm contacts.

27.4.4. Pressure relief device with directional shield, semaphore and alarm contacts.

27.4.5. Dehydrating breather.

27.4.6. Sudden pressure relay.

The LTC operating mechanism shall be a Reinhausen Manufacturing Inc., 27.5TAPMOTION MD-III (Reinhausen/SMUD standard project# 4647967) and include the following:

27.5.1. Motor and drive mechanism voltage, 240VAC.

27.5.2. Hand crank for manual operation with electrical interlock to prevent LTC operation by motor drive while the hand crank is engaged.

27.5.3. Tap Position Indicator.

27.5.4. Control Equipment and Accessories.

27.5.5. Enclosure, Terminal Blocks, Sensing Apparatus.

An operation counter shall be provided to register the accumulated number of tap 27.6changer operations performed.

Oil that immerses the LTC components shall be physically isolated from oil contained 27.7within the power transformer tank. Maintenance of the LTC mechanism shall not require draining any oil from the main transformer tank. The LTC compartment shall be provided with an inspection door to facilitate inspection and maintenance.

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An LTC nameplate with information on manufacturer, type, model/serial number, 27.8

BIL, rated through current, motor drive mechanism specifications, year of manufacture, oil volume, etc. shall be provided separate from the main nameplate.

The LTC voltage regulating control shall be Beckwith Model M-2001D with Beckwith 27.9Model M-2270B adapter panel. The control shall be flush-mounted on a swing panel in the control cabinet. The LTC control shall also include RS-485/DNP3.0 Level 2 communications (selectable baud rate from 300 to 115200) and Beckwith Model M-2025D (±1 mA) tap position monitoring features. The control shall be wired for independent voltage sensing and control power inputs. All LTC control alarm outputs shall be wired to terminal blocks. The control shall include a pair of voltage sensing jack-in test points.

A back-up control shall be provided to deactivate the LTC when the voltage exceeds 27.10the bandwidth setting. The back-up control shall be Beckwith Model M-0329B, or SMUD approved equal, with 120-volt band center and 1 volt fixed dead band options. The back-up control shall also be connected to utilize the overvoltage runback control feature and output alarm contact for a remote alarm wired to terminal blocks.

Equipment shall include the necessary line drop compensator, current transformer, tap 27.11changer voltage regulating control, tap changer back-up control, voltmeter, associated indicating and control devices. Voltmeter shall have a suitable kilovolt scale to indicate line-to-line voltage for use with a line-to-neutral connected potential transformer with a ratio of 60:1.

The line drop compensator current transformer shall be wired through a two-pole 27.12shorting jack-in test switch, States type MTS C202-C, or SMUD approved equal.

Spare contacts (two Form C) shall be provided that indicate the maximum raise 27.13position and minimum lower position of the tap changer.

The transformer shall be capable of being operated in parallel and the necessary 27.14control relays (Beckwith model M-0127A & M-0115A) and equipment to operate alone or in parallel shall be included. Equipment to limit circulating current when two (2) or more transformers are operated in parallel shall be included. Transformer paralleling controls shall be wired to terminal blocks for external connections between transformers and other equipment.

Load tap changer position indication shall be provided for local visible display and 27.15analog feedback (±1 mA for ±16 tap positions, 16 raise and 16 lower) to the LTC voltage regulating control. The tap position indication shall consist of a programmable Position Monitor – Intelligent Controls model 1250B and a Synchro-Transmitter – Intelligent Controls model 1292KS or SMUD approved equal. Power for the monitor shall be a separately fused input from the load tap changer control power. The monitor output shall be connected via continuous shielded cable to a terminal block

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through a two-pole shorting jack-in test switch, States type MTS C-202-C, or SMUD approved equal. The synchro-transmitter shall be geared to the tap changer such that the transmitter rotation shall be less than 360° for proper memory action from 16 raise to 16 lower positions.

28. ACCESSORIES AND CONTROL DEVICES

The Contractor shall furnish steel NEMA 4 cabinets on the transformer for power and 28.1control functions. The bottom of the control cabinets shall be located at 42” above the transformer base.

The main control cabinet interior shall be divided into two (2) sections. The outer 28.2front section shall be dead front, provided with the operating personnel controls, switches and indicators, flush-mounted on a hinged NEMA Type 1 safety barrier, secured with a non-lockable latch mechanism.

The inner rear section shall enclose the exposed-terminal surface-mounted controls, 28.3devices, terminal blocks and wiring.

Each cabinet shall have the following features: 28.4

28.4.1. White interior finish color.

28.4.2. Thermostatically-controlled strip heaters for space heating. Voltage applied to the space heaters for operation shall be 120 volts. Space heaters shall be rated for 240 volts. An adjustable thermostat shall be set to control the heaters at 25C and below. The thermostat shall be located in the transformer main control cabinet.

28.4.3. Lights and light switch.

28.4.4. Screened weather protected ventilation top and bottom.

28.4.5. Hinged door with provision for padlocking.

A ground bus inside the control panel for neutral and ground connections wired to a 28.5transformer ground pad. The ground bus shall be drilled and tapped and provide a minimum of 20% spare holes. All control cabinets and hinged panels shall be electrically bonded and positively connected to the transformer ground.

A 120V AC, 15A convenience outlet with ground fault protection (Leviton 7599 or 28.6SMUD approved equal).

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Devices and relays inside the cabinets shall be selected to operate properly to 60°C 28.7

internal ambient temperature.

Circuit breakers shall be thermal-magnetic type and shall be 50°C ambient 28.8compensated.

The transformer shall include two temperature monitors. One Electronic Temperature 28.9Monitor and one mechanical temperature monitor.

28.9.1. The Electronic Temperature Monitor shall be a Qualitrol type 509DW model ITM509DW-00263528, or SMUD approved equal, to monitor the hot spot winding temperature for each of the HV, LV and TV windings and the transformer top oil temperature. The transformer winding temperature shall be monitored using fiber optic sensors installed in the transformer windings. The fiber optic sensors shall be connected to the Qualitrol optical hot spot module. The RS-485 output of the optical hot spot module shall be communicate to the 509DW. HV, LV and TV CT’s shall provide 0-5 amp wire loop for installation of clamp on auxiliary CT’s to provide winding temperature inputs to the 509DW. The transformer oil temperature shall be monitored using a 100Ω RTD installed in an uncompensated well and connected to the Qualitrol 509DW. Ambient temperature shall be monitored using a 100Ω RTD connected to the Qualitrol 509DW.

28.9.2. The 509DW shall be located inside the transformer control cabinet and shall be visible through a window in the outer control cabinet door.

28.9.3. DNP 3.0 communications shall be wired out to terminal blocks for customer connection to remote supervisory indication. A fiber optic standard ST connection shall also be provided for remote communication.

28.9.4. The electronic temperature monitor shall have eight Form C alarm contacts with a minimum of four set points for cooling control, alarm and tripping (Bank 1 fans on/off, Bank 2 fans on/off, High temperature alarm, High temperature trip).

28.9.5. The mechanical temperature monitor shall be a Qualitrol 104 Series model TR6000B-00267870 with temperature range of 0 – 160˚C, 4 contacts and PT100Ω. A compensated thermal well shall be provided for the mechanical temperature monitor. The mechanical temperature monitor shall be utilized for backup fan control, alarm and tripping. The

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mechanical winding temperature monitor shall have four field adjustable output contacts.

The fan control contacts shall be configured with normally closed contacts for a “fail 28.10safe design” so the fans will start with contacts in shelf state. The alarm and trip contacts will be wired in a non-fail safe configuration.

The winding hot spot temperature rise over top oil temperature calibration curve shall 28.11be provided to SMUD. Winding and oil temperature rate of rise curves shall be based on the data accumulated during the transformer heat run testing.

Two (2) fiber optic winding temperature sensors shall be provided at the hottest spot in 28.12each winding of each phase and brought to the control cabinet. One (1) set of fiber optic sensors shall be terminated in the control cabinet as test points. One (1) set of fiber optic sensors shall be terminated on the Qualitrol 509DW to provide temperature input data. Fiber optic temperature sensors shall be compatible with Neoptix T2 and meet ASTM D2413 and ASTM D149.

The fiber optic sensor cables shall penetrate the transformer tank wall using a welded 28.13(PLT-201) tank wall plate assembly.

All fiber optic cables outside the tank and control cabinet shall be protected by 28.14junction boxes or conduit.

All fiber optic sensors shall be monitored during factory temperature rise testing, with 28.15results used to correctly calibrate the mechanical winding temperature monitor.

Provide one (1) each Portable Fiber Optic Thermometer Qualitrol KIT-057-1 for field 28.16verification of sensor readings.

Contractor shall furnish an oil type flange mounted Qualitrol rapid pressure rise relay 28.17(RPRR), Model 900-003-02 or SMUD approved equal for the main tank and LTC compartment. A continuous wire assembly without splice shall be provided between RPRR and the transformer control cabinet. A seal-in relay, Qualitrol 909-300-01 or SMUD approved equal shall be provided and mounted in the control cabinet with normally open contacts terminated for use as trip and alarm functions. The cable from the RPRR to the control cabinet shall be protected by a weatherproof conduit. A shut off gate valve shall be provided between the transformer tank and the relay for purposes of isolation and testing. This valve and RPRR assembly shall be mounted on the side of the main tank, accessible for testing from ground level. The Contractor shall furnish a field test kit Qualitrol KIT-013-1 for testing the RPRR.

All alarm devices shall have two Form C contacts. All alarm points and 28.18interconnections with other equipment and devices shall be wired to terminal blocks.

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Fuses and/or breakers used in the circuit shall be coordinated. 28.19

All meters and instruments (excluding the Buchholz gas meter but including the 28.20Buchholz gas sampling device, if provided) that have to be reset shall be mounted less than six (6) feet above the base of the transformer. Visual indicating devices mounted higher than six feet of the transformer base shall be tilted for ease of reading from the ground within 5 ft. of the transformer.

Alarm contacts shall be electrically separate, open during normal conditions, self-reset, 28.21suitable for closing 5 Amperes, carrying 3 Amperes continuously and opening 1.5 Amperes at 125 Volts DC. Control contacts shall be electrically separate, open during normal conditions, self-reset, suitable for closing 30 Amperes, carrying 10 Amperes continuously and opening 3 Amperes at 125 Volts DC.

All analog transducer and auxiliary CT outputs shall have a built-in current test jack, 28.22or be connected through a miniature test switch ABB Type FT, or SMUD approved equal.

Signal lamps associated with checking for the operability of the control circuit shall be 28.23LED type.

The following control devices shall be provided, with contacts wired to terminal 28.24blocks in the main control cabinet:

28.24.1. Loss of AC voltage relay (27-1, 27-2 and 27-3) with integrated time delay, self-resetting, 1.5 to 15 seconds, time delay on pickup to give alarm upon loss of voltage for a set time.

28.24.2. 125VDC Relay (2X) to alarm for high temperature pending trip condition (loss of fan voltage & high winding temperature).

28.24.3. 125VDC Timing relay (2-1), self-resetting, 6 to 60 minutes, with a time delay pickup to be used in SMUD’s transformer protection scheme to de-energize the transformer after a 30 minute time period, high temperature trip.

28.24.4. Loss of DC voltage relay (27DC), 125VDC, to indicate the loss of DC Power.

28.24.5. Temperature Monitor (49) Failure Alarm.

28.24.6. Pressure Relief Operation.

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28.24.7. Sudden Pressure Trip Alarm contact (63X1) for sudden pressure trip

indication. Sudden Pressure Trip contact (63X2) for trip contact used in the SMUD protection scheme.

28.24.8. Sudden Flow Trip Alarm (if provided).

28.24.9. Membrane Bag Rupture Alarm (if provided).

Temperature and miscellaneous controls shall be as shown on attached example 28.25reference drawings EDS-E2B-D001thru EDS-E2B-D007. The Contractor shall utilize these drawings in his design and submittals, modified to show the specific components and wiring configuration used. Any discrepancies between these drawings and this specification shall be brought to the attention of SMUD for resolution.

All electrical components shall meet or exceed IEEE standards. 28.26

The transformer shall be provided with a permanently attached engraved stainless steel 28.27diagrammatic nameplate provided with information furnished as per Table 9 of IEEE C57.12.00. The nameplate shall also state design ambient temperatures of 40°C average and 50°C maximum.

A nameplate shall be provided with the transformer showing the exact physical 28.28representation of the valves and the oil preservation system furnished. This valve identification nameplate shall identify each valve provided by size and description on the transformer outline diagram. A nameplate for lifting, jacking and rolling the transformer shall be provided.

All Accessories and control devices shall be designed in accordance with IEEE 693 28.29and this specification:

28.29.1. All accessories and control devices (non-tank components) including cabinets, equipment, and external racks/supports shall be designed in accordance with IEEE 693 Annex D Section D4.1.2.

28.29.2. All information shall be fully documented and provided in the structural report.

29. CONTROL POWER

29.1.1. The transformer auxiliary equipment and controls shall be rated for 120/240 VAC, 60 Hz, 1Ø, grounded neutral service. Each auxiliary

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equipment power and control circuit shall have separate short circuit and current overload protection.

29.1.2. Transformers shall be provided with screw terminal blocks in the control cabinet to accept external SMUD provided single-phase, 120/240 VAC auxiliary control power. Separate terminal blocks shall be provided for the LTC controls and the cooling equipment controls.

29.1.3. A separate terminal block shall be provided for an ungrounded 125 VDC incoming power supply. All tripping, alarm, and associated devices shall be rated for 125 VDC operation.

29.1.4. Each AC and DC functional circuit shall be protected with a thermal magnetic breaker with auxiliary trip contact. The auxiliary trip contacts shall be wired to terminal blocks.

30. SMUD CABLES, WIRING AND LABELING

30.1.1. Conduit entry for all SMUD installed cables shall be provided in the bottom of the control cabinet. SMUD will install conduits/cables through the control cabinet access cover plates.

30.1.2. All transformer equipment requiring electrical interconnection with other equipment shall have all leads brought to terminal blocks located in the control cabinet. All control, power, alarm, and auxiliary equipment shall be completely wired at the factory. All device designations, wiring, terminations and labeling shall be provided in accordance SMUD’s TECHNICAL SPECIFICATION SS1009 – DISTRICT’S WIRING REQUIREMENTS (attachment to this specification). NOTE - All wiring shall include Contractor furnished and installed identification sleeves with ink printed destination of the opposite end of each wire.

30.1.3. All wiring external to the control cabinet shall be installed in rigid steel conduit. Flexible internally armored liquid tight conduit is acceptable for final connections between the rigid steel conduit and the accessory equipment only. Maximum length of flexible conduit from rigid conduit to accessory equipment is 24”.

30.1.4. All wiring from components removed for shipment shall be tagged to re-connect to the control cabinet terminal blocks during on-site assembly.

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30.1.5. All conduit connections shall be weather tight. Conduit shall not enter the

top of cabinets, enclosures or components.

30.1.6. Fan motor leads and terminations/plugs/receptacles shall be weatherproof.

30.1.7. The transformer tank shall not be used as ground return paths for control circuits. Ground connections shall be installed with insulated wire connected to a ground bus.

30.1.8. Control and power circuit wiring shall not be combined in conduits or on terminal blocks. Separate power conduits and terminal blocks shall be provided for power circuits. Wiring for (HV) and (LV) current transformers shall be segregated from each other and from power circuits.

30.1.9. All components in the control cabinet shall be labeled in accordance with the drawings.

31. COOLING SYSTEM

Cooling equipment shall consist of transformer oil, radiators, fans and controls 31.1(ONAN/ONAF/ONAF).

All groups of cooling equipment shall operate in parallel from the same power source. 31.2Isolation methods for grouped fans shall be provided for de-energizing individual groups while other fan groups continue in normal operation.

The cooling equipment controls shall be fully automatic in operation. A selector 31.3switch mounted in the transformer control cabinet shall be provided for changing the sequence of automatic operation of the fan groups. No single fault in the control circuitry shall cause a loss of more than one half of the cooling system capability. Manual-auto (no off position) control switches shall be provided in the control cabinet to allow testing and maintenance of cooling fans.

The control cabinet shall be provided with elapsed time meters to record operating 31.4time of the forced cooling equipment.

Integrally mounted, removable radiators shall be provided to maintain the specified 31.5transformer rating. Radiators and accessories shall be constructed to withstand the vacuum and pressure conditions specified for the main tank.

Each radiator shall be independently mounted and provided with a drain plug at the 31.6bottom, an air vent at the top, and isolating valves so that a radiator may be removed with the transformer out of service and without draining the oil in the main tank.

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Isolation valves shall be replaceable, flange-mounted, manually operated shutoff valves with provisions for padlocking in open or closed position. Oil tight covers shall be provided for each connection (to be used when cooling equipment is detached). Radiators shall be of the self-draining type with threaded bosses with brass pipe plugs for draining and venting. Lifting lugs shall be provided on each radiator for lifting by a crane.

The transformer tank shall include one spare set of flanges with valves for the addition 31.7of an external transformer cooler.

Transformer cooling fans shall feature an OSHA approved hot dip galvanized fan 31.8guard and totally enclosed, weatherproof, sealed anti-friction bearing NEMA frame motors. Motor bearings shall be designed for continuous as well as intermittent duty.

Motors associated with cooling equipment shall have built-in manually reset thermal 31.9overload protection, be permanently lubricated and shall be in accordance with NEMA MG1.

Supports for arresters, conservator tanks, etc., mounted above the cooling equipment 31.10must be designed in such a way that there is no disassembly required to access the cooling equipment for removal.

Unconfined gasketed joints connecting radiators to the transformer tank shall not be 31.11designed as structural supports. A separate, independent structural support system shall be utilized.

The radiator structural supports shall adequately brace the radiators in all directions. 31.12The bracing shall include both upper and lower horizontal bracing for the radiator out-of-plane seismic and wind loads. Bracing for vertical dead loads and seismic uplift loads shall also be included.

The seismic and wind analysis of the radiators shall meet the requirements of both 31.13IEEE 693 and this specification:

31.13.1. Where open structural members are used, a torsional and torsional deflection analysis of the member shall be performed.

31.13.2. All information shall be fully documented and provided in the structural report.

32. OIL PRESERVATION SYSTEM

Either an inert gas pressure system or a sealed bladder oil preservation system shall be 32.1provided as the oil preservation system for the transformer. All equipment necessary

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to make the system operable shall be included. The Contractor proposal documents shall include information on the type of oil preservation system to be provided with the transformer.

All tanks, enclosures and valves subject to the operating pressures of the oil 32.2preservation system, as applicable, shall be designed to withstand 125% of the maximum operating pressures, positive or negative, of the oil preservation system furnished.

The transformer main tank and LTC compartment shall have a mechanical re-closing 32.3pressure relief indicating device with directional shield, semaphore and alarm contacts (two Form C) wired through terminal blocks in the main control cabinet for remote alarm. Main tank and LTC compartment pressure relief contacts shall be wired in parallel to the terminal blocks. The device shall be a Qualitrol LPRD series 213 or SMUD approved equal.

Valves shall be provided to permit filling, draining, and purging the gas space. 32.4

The transformer shall also be provided with valves suitable for performing the 32.5following functions:

32.5.1. 2-inch upper fill valve with threaded pipe plug and interior deflector plate located in upper gas space on tank sidewall.

32.5.2. 2-inch lower drain valve with threaded pipe plug and 3/8” sampling valve located at bottom on tank sidewall (no drain located on bottom of transformer tank).

32.5.3. A 3/8” oil sample valve with lockable case located on the tank sidewall approximately 4’-0” (+ 6”) above transformer base.

32.5.4. 4-inch valve for vacuum pump connection located on top of tank. Valve to have male threaded connection with pipe cap.

32.5.5. Isolating each oil connection to and from each radiator.

32.5.6. Draining oil from each radiator.

32.5.7. LTC tank lower drain and upper vent valves with threaded pipe plugs.

32.5.8. Isolating the sudden pressure and fault pressure relays.

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32.5.9. Isolating the conservator tank, if applicable.

32.5.10. Isolating the gas detector relay, if applicable.

The inert gas pressure system shall be able to maintain automatically an atmosphere of 32.6dry nitrogen gas in the space above the oil level in the transformer and shall include the following features:

32.6.1. Sufficient expansion space above the oil level in the transformer shall be provided to prevent nitrogen exhaust to atmosphere under any anticipated load and/or temperature conditions and to cushion the effect of a sudden rise in internal pressure due to gas generated by a fault, to prevent rupture of the tank.

32.6.2. The transformer shall have an adjustable dial type oil level gauge in the main tank with dual low-level alarm contacts wired through terminal blocks in the main control cabinet for remote alarm. The gauge shall be by Qualitrol Bulletin QT2-220 or SMUD approved equal.

32.6.3. Three-stage pressure reducing system that reduces the cylinder pressure of 2500 psi to approximately 0.5 psi to control the flow of gas to the transformer tank.

32.6.4. Pressure-vacuum bleeder.

32.6.5. A transformer tank dial-type pressure/vacuum gauge, with a minimum range of plus/minus 10 psig and high and low pressure alarm contacts (two form C).

32.6.6. Gas cylinder pressure gauge with alarm contacts for low cylinder pressure wired to terminal blocks in main control cabinet.

32.6.7. Valves shall be provided to permit purging the gas space and testing the seal on the tank by admitting dry nitrogen under pressure.

32.6.8. Adequate amount of bottled nitrogen gas shall be furnished to place the transformer in service.

32.6.9. Nitrogen bottle valve shall be CGA type 555 with male threads. Regulator fitting for attachment to bottle shall be compatible.

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32.6.10. The nitrogen control equipment, including adequate space for nitrogen

bottle, shall be protected by an easily accessible weatherproof enclosure mounted on the transformer tank at ground level.

The sealed bladder type of preservation system (if provided) shall be a suitable 32.7substitute for the inert gas pressure sealed tank system. The system shall be suitable for operation at no load and full load between the ambient temperatures of 50°C and -10°C without the entrance of air or moisture into the tank and without allowing the oil level to fall below the low oil level and to fall below any part requiring transformer oil for insulation properties.

A shut-off valve, capable of holding the full head of oil in the expansion tank without 32.8leaking, shall be provided in the oil line between this tank and the main oil tank.

All high points shall be separately piped to the conservator (if provided) through the 32.9gas accumulator relay to prevent formation of gas pockets. In addition, the following features shall be included:

32.9.1. Low liquid level gauge in the conservator (if provided) with dual alarm and trip contacts (two Form C). The gauge shall be by Qualitrol Bulletin QT2-220 or SMUD approved equal.

32.9.2. An air-cell integrity monitor to detect failure of the air-oil sealing system with alarm contacts (two Form C).

32.9.3. A gas accumulator relay with alarm contacts (two Form C), Buchholz type, P & B Weir 3DE/VO or SMUD approved equal, in the pipe connected to the conservator. The Buchholz relay shall be provided with a gas sampling device, Cedaspe RG3.2 or SMUD approved equal, at a convenient operating height for removing gas samples without de-energizing the transformer.

32.9.4. The gas relay shall be provided with an auxiliary seal-in relay with hand reset, located in the control cabinet. The seal-in relay shall be a Qualitrol model 909-300-01.

32.9.5. The system shall prevent air and moisture from contact with the oil through the use of a flexible rubber air cell in the conservator tank. A positive oil pressure must be maintained on all gaskets above the tank cover.

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32.9.6. The transformer shall be supplied with a maintenance free breather. The

breather shall be a Waukesha Maintenance Free Dehydrating Breather (MFDB) or SMUD approved equal.

33. TRANSFORMER OIL

A sufficient quantity of transformer oil shall be furnished with the transformer for 33.1filling each tank and radiator to the proper level. The transformer shall be shipped in a weatherproof configuration, preferably filled with all oil required for full load operation. Oil provided for the load tap changer shall be the same type as the oil in the main tank.

The initial oil filling of the transformer shall be made at the factory under acceptable 33.2vacuum methods designed to eliminate entrained air from within the tank and windings.

Oil not shipped in the transformer shall be delivered to the substation site in sealed 33.3tank truck lots certified clean and dry. The tank truck shall include oil pump and hoses suitable for connection with 1” to 2” quick connector which shall also be sealed. The Contractor shall be responsible for coordinating oil delivery.

The Contractor shall provide SMUD with the characteristics of the transformer oil to 33.4be supplied. SMUD will test the oil upon delivery and use these characteristics as criteria for acceptance or rejection of the transformer oil.

The transformer oil shall be Type II, anti-oxidant, inhibited mineral oil, in compliance 33.5with ASTM D3487 and shall contain no more than 6 ppm water when tested in accordance with the procedures of ASTM D1533 (Karl Fischer Method). It shall test at least 30kV upon receipt at the job delivery point when tested in accordance with the procedures of ASTM D877. Oil samples shall be in accordance with ASTM D923. The oil will also be tested prior to being placed in the transformer or LTC per ASTM D1275B. The oil is to be corrosive sulfur free. Oxygen ppm shall be less than 3000. These requirements also apply to any required makeup oil.

Polychlorinated Biphenyls shall be non-detected when tested in accordance with 33.6ASTM D4059 and oil shall be certified as non-PCB according to applicable Federal and State Regulations. The transformer nameplate shall read “contains less than 1 ppm of PCBs at time of manufacture”.

Insulating oil sampling and test procedures at the factory shall conform to the 33.7requirements of ASTM D117.

The oil shall be new, unused, inhibited, refined and compatible with existing acid 33.8refined oils and with other oils available at the time of transformer delivery. If the

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dielectric test strength of any oil received in the field, whether shipped separately or in the transformer, tests less than 30kV when tested in accordance with the procedures of ASTM D877, the Contractor shall provide all labor, supervision, material and equipment required to furnish the oil quality specified.

The performance of the transformer insulation system shall meet all the requirements 33.9of these specifications when oil samples taken from the completely filled transformer have a dielectric test strength of only 26kV when tested in accordance with the procedures of ASTM D877.

34. SOUND LEVEL

The maximum average sound level, as measured per IEEE C57.12.90, shall not exceed 34.180 dBA at the transformer second (maximum) ONAF rating. Sound level measurements shall include noise produced from all cooling equipment required for the transformer rating.

The sound levels shall be measured at the tap setting (bridge position) that produces 34.2the maximum transformer noise. In addition, any directional noise component, i.e. NEMA individual sound measurement, shall not exceed the maximum average by more than three decibels.

35. TESTING

All testing shall be made in accordance with IEEE Std. C57.12.90. Tests shall be 35.1made at the manufacturing test facility.

The Contractor shall not commence the testing of the unit without the final approval of 35.2all drawings by SMUD including control schematics and wiring diagrams.

The Contractor shall provide SMUD access to the transformer manufacturing 35.3facilities.

SMUD may perform inspections and witness all required testing. The Contractor shall 35.4notify SMUD at least four (4) weeks in advance of the date of the tests and coordinate the date of final acceptance tests with SMUD to facilitate witness testing.

SMUD, at its option and cost, may require a short-circuit test be performed on any of 35.5the transformers. When required, the test shall be performed per IEEE C57.12.90.

The Contractor shall notify SMUD of any unusual event or damage occurring during 35.6the fabrication or testing of the transformer and of all tests that do not meet the specified acceptance values.

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SMUD reserves the right to inspect such damages or test failures. SMUD shall be 35.7

included in the remediation decision, and corrective measures to rectify such damages or failures shall be subject to acceptance by SMUD.

The resistance, polarity, phase relation, turn ratio, no-load loss, percent impedance, 35.8temperature rise (when applicable), and load loss tests shall precede dielectric tests.

The dielectric test sequence shall be arranged so that impulse tests precede the power 35.9frequency tests, and the final dielectric test performed shall be the induced overvoltage test. Repeat the excitation loss and excitation current tests after impulse testing.

Routine test shall be made on every transformer to verify that the product meets the 35.10design specifications.

Routine design and other tests shall be made in accordance with IEEE Std. C57.12.90. 35.11

Design tests shall be made on a transformer of a new design to determine the adequacy 35.12of the design.

Transformer secondary circuits shall be tested for all low voltage control wiring, 35.13associated control equipment and current transformers

The Contractor shall provide copies of certified test reports covering shop tests 35.14conducted on the assembled transformers.

Oil samples shall be taken and given a Transformer Condition Assessment (TCA) test 35.15before and after dielectric tests.

Oil samples shall be analyzed for dissolved gases and oxygen (ppm & percent relative 35.16saturation) before transformer testing begins and after transformer testing is completed.

Oxygen concentration shall be less than 3,000 ppm. 35.17

Relative oxygen saturation must be less than 35% before transformer testing begins 35.18and after transformer testing is completed. Oxygen saturation data shall be included in the test report.

SMUD test limits for increases during transformer testing are: 35.19

Acetylene 0ppm

Methane 2ppm

Ethane 1ppm

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Ethylene 1ppm

Hydrogen 10ppm

CO 5ppm

CO2 150ppm

The ratio of CO2 to CO shall be a minimum of 7.0. 35.20

Each transformer shall be completely assembled in the factory by Contractor prior to 35.21testing, and shall be tested as specified in IEEE C57.12.00 and NEMA TR 1 using the methods prescribed in IEEE C57.12.90.

All components tested with a transformer shall be the same components furnished and 35.22delivered with the transformer.

The Contractor shall calibrate the equipment used for testing to National Bureau of 35.23Standards (NBS) 1206 and a certificate shall be made available for verification.

The Crossed P.A. Lead Test for RMV-II, Reinhausen Standard document CI7006:02, 35.24shall be performed prior to energizing the transformer for testing to verify proper connection of the load tap changer.

All tests listed, as "ROUTINE TESTS" under Section 8 of IEEE C57.12.00 shall be 35.25performed on each power transformer. Test results shall conform to Section 9, Tolerances.

Additional tests shall be performed on each power transformer as indicated below: 35.26

35.26.1. The transformer shall be tested for partial discharge on all windings using either the apparent charge or the radio influence voltage (RIV) method per IEEE C57.12.90 and IEEE C57.113.

35.26.2. The 7200 cycles test at enhancement level shall be incorporated into the test.

35.26.3. For the apparent charge test, no partial discharge greater than 300 Pico-coulombs shall be acceptable.

35.26.4. Alternatively, for the RIV test, the measured microvolt level above background shall not exceed 150 microvolts at any time during the test.

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35.26.5. The partial discharge test shall be performed after all other dielectric tests

are completed. The curve of the data obtained in the test shall be included in the test report.

Lightning Impulse Tests: 35.27

35.27.1. The lightning impulse tests shall be performed including chopped wave and full wave in accordance with IEEE C57.12.90 and IEEE C57.98. Measured core loss after impulse test should not be increased by more than one half percent.

35.27.2. SMUD may reject any transformer on which impulse testing is failed twice.

Insulation Resistance Test: 35.28

35.28.1. The transformer shall be tested for insulation resistance per IEEE C57.12.90.

35.28.2. All resistance measurements shall be corrected to 20°C.

35.28.3. The tests shall be performed on the transformer filled with oil and with appropriate bushings interconnected to measure the resistance from primary to ground, secondary to ground, and from primary to secondary.

35.28.4. The tests shall be performed utilizing an applied potential of 2500 volts DC.

35.28.5. In addition, a test shall be performed between the core and ground utilizing an applied potential of 500 volts DC.

35.28.6. The test values and reference temperatures shall be provided in the test report.

Insulation Power Factor Test: 35.29

35.29.1. The transformer shall be tested for insulation power factor per IEEE C57.12.90 with oil and bushings in place.

35.29.2. The power factor tests shall be conducted using an impressed voltage of 10kV at 60 Hertz.

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35.29.3. The power factor values of the insulation system shall not exceed 0.35% at

20°C.

The tests shall be conducted as follows: 35.30

Test No. Winding

Energized Winding

Grounded Winding Guarded

1. Primary Secondary - -

2. Primary -- Secondary

3. Secondary Primary --

4. Secondary -- Primary

Bushings shall be tested as per IEEE C57.19.00. The test data of performance tests 35.31such as power factor measurements, etc. and bushing serial numbers shall be provided in the test report.

The average sound/octave band level of the transformer shall be measured in 35.32accordance with IEEE C57.12.90.

Audible sound level tests shall be performed on the transformer at 100% excitation 35.33voltage for base and maximum transformer rating with the corresponding rating cooling equipment operating.

A temperature rise test shall be performed, as a minimum, on the first transformer of 35.34each rating manufactured under this specification. The temperature rise test shall be performed per IEEE C57.12.90 for both the ONAN and top ONAF ratings, and shall include a 110% over excitation temperature rise test. The test shall be performed at the tap connections resulting in the highest losses. The test results shall include all test data taken, including bottom oil temperatures. The hottest spot temperature rise calculation shall be performed using the "maximum eddy-current watt loss method." Dissolved gas-in-oil analysis shall be made before and after temperature rise tests. Thermal scans shall be performed during the ONAF temperature rise test. All four sides of the tank and the cover shall be scanned. The data shall be presented in the certified test report.

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Additional excitation current test: Each test shall include both an excitation current 35.35(magnetizing current) and a watts loss measurement. These tests shall be performed on the high voltage winding of the transformer. Test voltage shall be 10 kV AC, however if 10kV exceeds the L-G rating of the winding, a test voltage shall be selected as the highest voltage, rounded to the nearest 1000 volts, not to exceed the L-G rating of the winding. All load tap positions shall be tested in the center de-energized tap position for all three windings, plus each primary winding de-energized tap position shall be tested with the LTC in neutral. All measurements shall be made to exclude any current not associated with excitation of the winding being tested. The following circuit shows the excitation current test connections for wye-connected windings.

Winding Resistance Test: Winding resistance measurements shall be performed per 35.36IEEE C57.12.90 for all windings with primary winding in each tap position. The resistance values and reference temperatures shall be provided in the test report.

X/R Test: The Contractor shall furnish X and R-values based on test data so that an 35.37equivalent transformer X/R ratio can be determined in accordance with C37.010.

Zero-phase-sequence Impedance Test: A zero sequence impedance test shall be 35.38performed in neutral tap position. The sequence network shall be provided as part of the certified data. The network shall be derived from actual test per C57.12.90.

Sweep Frequency Response Analysis (SFRA): Perform SFRA on the completely 35.39assembled transformer in accordance with the following:

35.39.1. NOTE - This test shall be performed with an Omicron test set or SMUD approved equal. The test results shall be provided in electronic format.

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35.39.2. The test performed shall be made over a frequency range of 20 Hz to 2

MHz.

35.39.3. The test set shall be capable of measuring sufficient dynamic range, over the frequency range in order to accommodate most transformer test objects (+20 to –100 dB).

35.39.4. Both the Magnitude and Phase of the calculated transfer function shall be presented.

35.39.5. Frequency response measurements shall be made using a log-based frequency scale for good resolution.

35.39.6. An interference bandwidth of less than 1/5 of the measured frequency must be used for each measurement frequency.

35.39.7. The transformer shall be as close to ‘in service’ condition as possible; oil filled and bushings installed. Current transformers shall be configured for in-service conditions.

35.39.8. The test equipment shall be within the published calibration interval.

35.39.9. The test equipment shall be grounded to the transformer under test, and the transformer tank shall be grounded to the main systems.

35.39.10. All test lead connections shall be made directly to the bushing terminals.

Two measurement types shall be performed: 35.40

35.40.1. Open Circuit Test (OC) - An open circuit measurement is made from one end of a winding to another with all other terminals floating. These tests can be categorized as; High Voltage, Low Voltage, Primary, Secondary, Series, and Common.

35.40.2. Short Circuit Test (OC) - The short circuit measurement is made from one end of a high voltage winding to another while another winding is shorted.

35.40.3. The LTC be in the extreme raise position.

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35.40.4. DETC be in the position that is required by in service conditions; if not

specified the DETC should be placed in the nominal position.

35.40.5. The LTC and DETC tap positions shall be noted on the test report for each test.

35.40.6. Test connections. All windings should be tested as shown in the connection table below. The table differentiates between open circuit and short circuit tests. Y-Y Transformer:

Test Type Test # 3 phase

HV Open Circuit (OC) All other terminals floating

1 H1-H0 2 H2-H0 3 H3-H0

LV Open Circuit (OC) All other terminals floating

4 X1-X0 5 X2-X0 6 X3-X0

Short Circuit (SC) Short [X1-X2-X3]

7 H1-H0 8 H2-H0 9 H3-H0

Test to determine the impedance; positive sequence resistance, positive sequence 35.41reactance and zero sequence reactance between windings for each position of the no load tap changer. Include “T” impedance diagrams in the test report.

A CT ratio and polarity test in accordance with IEEE C57.13 shall be performed as 35.42part of the final top end control test on each CT. CT saturation tests shall also be performed. Data shall be included in the test reports. Drawings shall show the polarity marks.

Insulation resistance and complete function tests shall be performed on all control 35.43wiring and equipment.

Insulating liquid tests shall be performed for the following: 35.44

35.44.1. Dielectric break down voltage shall not exceed the limits specified in ASTM D877.

35.44.2. Acid neutralization number does not exceed the limits specified in ASTM D974.

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35.44.3. Specific gravity value does not exceed the acceptable values per ASTM

D1298.

35.44.4. Interfacial tension test insure that the tested oil does not include any soluble polar contaminants, refer to ASTM D971 or ASTM D2285.

The Contractor shall transmit to SMUD the certified test reports for all routine and 35.45additional tests at least two weeks prior to shipping the tested transformer. Test reports shall include all data listed in IEEE C57.12.00 and the following:

35.45.1. The test values and reference temperatures shall be provided in the test report.

35.45.2. Impulse Test: The certified test reports shall be submitted in a form similar to the Transformer Impulse Test Report illustrated in IEEE C57.98. The report shall include copies of all oscillograms or computer print-outs for all impulse tests performed. All impulse test records shall include current and voltage oscillograms recorded simultaneously and shall have the following information furnished: serial number of the transformer unit, test number, terminals to which tests are applied, type of impulse wave applied, wave identification (current or voltage) and baseline used. Each oscillogram in the report shall be accompanied by a diagram showing the test connections and component values of the circuit.

35.45.3. Sound Level Tests: The test reports of the sound level measurements shall include, for each position and height, the discrete frequency values and total sound levels.

35.45.4. A list of all test equipment used for each test with calibration due dates.

35.45.5. A calculated short-circuit limit damage curve.

35.45.6. The necessary procedures and test data to calibrate the hottest spot winding temperature indicator relays. This test data shall include load versus temperature curves for 30°C, 40°C and 50°C ambient, and the length of the time the transformer can be operated at overload condition as per IEEE C57.115.

35.45.7. “T” equivalent circuit impedance diagrams.

35.45.8. The following additional quantities shall be included:

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35.45.9. Top-oil rise over ambient at rated load.

35.45.10. Hottest-spot conductor rise over top-oil temperature at rated load.

35.45.11. Ratio of load loss to no-load loss at rated load.

35.45.12. Oil thermal time constant for rated load.

35.45.13. Winding time constant at hot spot location.

35.45.14. Normal life (years) of winding insulation.

36. PHOTOGRAPHS

The Contractor shall provide photographs of the transformer to SMUD prior to 36.1shipment. Photographs shall be 8” x 10” or alternatively digital photographs on a CD in .JPG format and shall show:

36.1.1. The internal construction of the transformer, all sides and top.

36.1.2. The transformer exterior, all sides and top. Exterior photographs shall be taken with all radiators, bushings, and accessories installed.

36.1.3. Close-ups of pertinent details such as no-load tap changer, LTC taps, and miscellaneous items.

36.1.4. The Contractor shall include printed copies of photographs in each instruction manual.

37. LOSS EVALUATION

Each Contractor shall submit in the transformer proposal the guaranteed no-load 37.1losses, the guaranteed load losses at maximum rated MVA, and the guaranteed auxiliary losses. The requirements indicated in IEEE C57.12.00, Sections 5.9 and 9.3 shall apply.

Guaranteed losses will be evaluated by SMUD to determine the equivalent first cost 37.2for owning and operating the proposed transformer. Losses will be evaluated at the following rates:

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37.2.1. No-load losses at 20°C $ 7,699/kW

37.2.2. Load losses at 85°C (at maximum rating) $ 2,331/kW

37.2.3. Auxiliary losses $ 1,161/kW

The Contractor shall test each transformer for no-load, load, and auxiliary losses. This 37.3test data shall be certified as correct and submitted to SMUD for approval prior to shipment.

SMUD will compare the tested losses submitted on the certified test report to the 37.4guaranteed losses submitted with the bid request for each transformer. If the tested losses exceed the guaranteed losses, the Contractor will be penalized at 1.5 times the above rates for each kW or fraction of a kW of excess losses (tested losses minus guaranteed losses) for each transformer.

No-load loss, load loss and auxiliary loss penalties will be assessed independently. 37.5Bonuses will not be awarded for tested losses that are less than guaranteed losses.

Any transformer with no-load losses or total losses that exceed the guaranteed losses 37.6by more than the tolerances for losses (10% no-load and 6% total) indicated in IEEE C57.12.00, Section 9.3, may be rejected by SMUD.

The Contractor shall contact SMUD prior to shipping any transformer whose losses 37.7exceed the IEEE tolerances. If SMUD accepts such transformer(s), the Contractor will be penalized at 2.5 times the above rates for each kW or fraction of a kW of excess losses (tested losses minus guaranteed losses) for each transformer.

38. BID SUBMITTAL

The proposal/bid documents submitted to SMUD shall include the following items: 38.1

38.1.1. The Contractor shall describe, in detail, all equipment to be supplied in accordance with these specifications. The Contractor shall indicate the manufacturer & part # of all accessory equipment to be supplied with the transformer.

38.1.2. The Contractor shall provide the quality assurance and quality control (QA/QC) procedures & documentation to be followed during the design & manufacturing of the proposed transformer.

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38.1.3. The Contractor shall provide a sample structural report, including

calculations and associated drawings, for a similar transformer built in accordance with the requirements for a high seismic qualification level as set forth in the latest edition of IEEE Standard 693, ANSI C57.12.10, this specification, and the latest revision of the applicable codes and standards.

38.1.4. The Contractor shall provide the short-circuit history or short-circuit test results for a similar transformer.

38.1.5. The Contractor shall provide a complete set of drawings and documentation for a similar transformer designed, manufactured and delivered in the past year. The documentation shall include the transformer characteristics/ratings, impedance, regulation, exciting current, efficiency, maximum losses, auxiliary cooling equipment power requirements, etc. and technical data of major components.

38.1.6. The Contractor shall provide the methodology for measuring top oil and winding temperatures. Show documentation to support the method used and corresponding test results for comparison.

38.1.7. The Contractor shall provide winding design details to withstand shipping and short-circuit forces.

38.1.8. The Contractor shall provide a reference list of ten (10) electric utility companies located in the United States (including reference contact information) that have received similar transformers over the past 5 years.

38.1.9. The Contractor shall provide a list of recommended spare parts. Each part listed shall include its unit price and lead-time of delivery. The unit prices of spare parts shall be for delivery along with the transformer as well as for delivery after the receipt of the transformer to SMUD. SMUD will determine the desired spare parts and include with the transformer order.

38.1.10. The Contractor shall provide comprehensive design, manufacturing, delivery, on-site commissioning and testing schedule with the proposal documents.

38.1.11. The Contractor shall provide all requested information and documentation required by this specification. The information will be used by SMUD in the bid evaluation process. The Contractor shall provide clarification responses to SMUD comments/questions concerning the proposal. SMUD

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reserves the right to reject the Contractor’s proposal if the information is incomplete, or if the information submitted is not adequate, or if the Contractor’s response time exceeds SMUD’s allocated duration in the evaluation schedule.

39. CONTRACT SUBMITTALS

The general requirements for the contract submittals provided to SMUD by the 39.1Contractor include the following items:

39.1.1. Drawings and technical data shall be developed and submitted in accordance with SMUD’s ENGINEERING SPECIFICATION W001 - Drawings and Technical Data (attachment to this specification). All drawings provided shall be in both “pdf” and AutoCAD 2007 “dwg” formats. Any special AutoCAD supporting files, such as plot styles, shall be provided. External reference files (XREF’s) shall not be used on AutoCAD drawings provided.

39.1.2. The Contractor shall use the SMUD AutoCAD border & title block for all drawings. SMUD will furnish an electronic file with SMUD AutoCAD border & title block following contract award.

39.1.3. The Contractor provided transformer wiring diagrams shall include an 8” wide by 16” high blank area on the right side for SMUD use.

39.1.4. A transmittal letter with a list of items being submitted shall be included for each submittal. The sequence of submission of drawings & documentation shall include all information necessary for SMUD to verify/approve the submittal. Transformer accessory equipment information shall be provided and include a description with manufacturer & part #.

39.1.5. The Contractor shall make the necessary revisions and shall resubmit all drawings & documentation that are not “APPROVED” by SMUD. Subsequent revisions shall be indicated on the drawings and include revision number, date, and subject in a revision block. The Contractor shall provide all required re-submittals on a basis that shall not interfere with the delivery dates indicated in the delivery schedule.

39.1.6. SMUD’s final approval of all transformer drawings & documentation shall be acknowledged by the Contractor prior to manufacturing the transformer. Any manufacturing work, fabrication or purchases prior to

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SMUD’s final approval shall be at the Contractor’s risk. The Contractor shall make any changes in the design which are necessary to make the transformers conform to the specification.

A complete set of SMUD approved submittals and required documentation shall be 39.2assembled and provided to SMUD by the Contractor prior to the start of transformer manufacturing. The following items shall be included in the set for the transformer:

39.2.1. Bill of Material – including item number corresponding to the transformer outline drawing location, description, manufacturer & part #.

39.2.2. Transformer physical drawings - including drawing index, legend, nameplate, outline, transformer tank, base, lifting details, jacking details, anchorage details, control cabinet equipment layout, oil preservation equipment, accessory equipment, lifting diagram, etc.

39.2.3. Transformer electrical drawings – including drawing index, legend, AC power schematic, fan controls, heaters, lights, receptacles, DC power schematic, accessory equipment schematic, LTC control schematic, alarm schematic, control cabinet wiring diagram, LTC wiring diagram, CT wiring diagram, accessory equipment wiring diagram, etc.

39.2.4. Structural analysis report including seismic qualification.

39.2.5. Preliminary instruction book.

39.2.6. Test plan, testing procedures and test report forms.

The following information shall be submitted by the Contractor and approved by 39.3SMUD before transformer shipment:

39.3.1. Complete test report.

39.3.2. Final documentation for all information required in section 39.2.

39.3.3. Final as-built drawings - including revision blocks indicating as-built status. A minimum of two (2) certified sets of printed drawings along with a digital media (USB flash drive or CD) copy in AutoCAD 2007 compatible format shall be furnished.

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39.3.4. Instruction books – Four (4) complete instruction books (paper copies) and

a digital media (USB flash drive or CD) shall be provided for each transformer.

39.3.5. One (1) complete licensed copy of the programming software for microprocessor based components on a digital media (USB flash drive or CD formatted for Windows compatible personal computers) shall be provided.

39.3.6. Final stamped and signed structural analysis report in accordance with the requirements of this specification. The report shall include all structural and seismic analysis requirements and documentation outlined in this specification. The report shall be based upon this specification and SMUD’s outline for structural analysis submittals. In addition to calculations and drawings, the report shall include all documents created during fabrication and production including steel material test reports, hardware material test reports, welding inspection reports, etc.

A comprehensive final schedule including design, manufacturing, testing and delivery 39.4milestones shall be submitted by the Contractor within four weeks after contract award. The schedule submittal shall include all major engineering milestones for the transformer including:

39.4.1. Design start.

39.4.2. Approval submittals (within 8 weeks after contract award).

39.4.3. SMUD reviews periods. A minimum of four weeks shall be provided in the schedule for SMUD engineering reviews.

39.4.4. Design completion.

39.4.5. Production start.

39.4.6. Major material orders and deliveries (core, windings, tank, radiators, bushings, and so forth).

39.4.7. Fabrication milestones including core, coils, tanking, wiring, and so forth.

39.4.8. Testing milestones.

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39.4.9. Final material, fabrication, testing reports, transformer photograph

submittals.

39.4.10. Production completion.

39.4.11. All modes of transportation to be utilized and approximate transit dates.

39.4.12. On-site delivery.

39.4.13. On-site assembly, commissioning and testing milestones.

Delivery submittal shall be submitted at least four weeks prior to delivery. 39.5

40. INSTRUCTION BOOK REQUIREMENTS

Four identical instruction books shall be included in the Final Submittal for the 40.1delivered transformer. All manuals shall be original publications. No photocopies will be allowed. Each instruction book shall be in bound volumes or 3-ring binders with a comprehensive index and separator tabs, identified by index items, separating major components and inserts.

The final submittal shall also include one (1) set of digital media (USB flash drive or 40.2CD) of the complete instruction manual. All installation, operation, maintenance and training information provided shall be in a searchable PDF format.

Each instruction book shall include the technical data specified in SMUD Technical 40.3Specification W001 and the following:

40.3.1. All final as-built drawings, reduced to 11 x 17 inch size and Z-folded to fold out for reading.

40.3.2. Operation and maintenance manuals for all complex control devices and components with adjustable calibration.

40.3.3. Copies of all test reports.

40.3.4. Microprocessor relay program instruction manuals.

40.3.5. Description and operation of the oil preservation system furnished with proper drawings/diagrams.

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40.3.6. Disassembly and core removal instructions.

40.3.7. Detailed instructions for transportation, lifting/rigging, jacking, and skidding. All transformer components, appendages, and accessories having a designated lifting/jacking/skidding/attachment location or requiring special handling procedures shall be clearly addressed in the instructions.

40.3.8. Photographs as specified.

40.3.9. Master Bill of Material.

40.3.10. Recommended spare parts lists.

40.3.11. Recommended maintenance schedule.

40.3.12. Site assembly and installation instructions.

41. QUALITY ASSURANCE

The Contractor shall have a formal Quality Assurance Program. The Quality 41.1Assurance Program shall consist of systematic procedures that provide confidence that the work is in accordance with these specifications.

The Quality Assurance Program manual shall be provided with the transformer 41.2proposal. The manual shall have descriptive information and details of the program. This information shall include program organization, documentation requirements, and quality control procedures.

Quality control procedures shall include testing procedures, acceptance criteria, repair 41.3methods, and the quality control requirements of these specifications.

The Contractor shall provide SMUD non-conformance reports for each manufacturing 41.4inspection and hold point, including the resolution for each item.

Documentation requirements shall include certification of material, audit and 41.5inspection records, deficiency corrections, and equipment calibration records.

The Quality Assurance Program shall be documented and presented to the individuals 41.6performing the work through a formal training program. Inspections and audits shall be performed and documented to ensure that the program is being followed.

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SMUD reserves the right to reject the Quality Assurance Program as inadequate and 41.7

request augmentation to the program prior to contract award.

42. INSPECTION AND HOLD POINTS

SMUD or its representative may at any time perform audits, inspections or observe the 42.1Contractor’s operations. The contractor shall cooperate and provide access to documentation, manufacturing or testing. SMUD’s Inspector shall be provided with full access to the facilities used for manufacturing the power transformer.

These inspections do not relieve the Contractor of his responsibilities for full 42.2compliance with all the requirements of these specifications.

SMUD will notify the Contractor of any situation where the work is not in accordance 42.3with the requirements of these specifications.

The Contractor shall schedule, implement and enforce the following manufacturing 42.4hold points, as a minimum, for the transformer:

43. PREPARATION FOR SHIPMENT

The transformer and all its components shall be carefully packed and loaded for 43.1shipment.

Special consideration shall be given to the preparation for shipment of all materials, 43.2components and devices to prevent damage during shipment.

The Contractor shall furnish SMUD with drawings and explanation of any special 43.3internal blocking and wedging installed only for transportation.

HOLD POINT RELEASE OF HOLD POINT

Start of fabrication SMUD authorization to proceed with fabrication.

Before tanking SMUD authorization to proceed with tanking.

Start of factory testing SMUD authorization to proceed with testing.

Shipment SMUD approval of test reports, final submittal, and authorization to ship.

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The Contractor shall install weatherproof covers over all equipment openings made 43.4

necessary for transformer shipment including, but not limited to: tank openings for bushings and radiators; and valve ends.

A separate weatherproof shipping container shall be provided for parts and tools. 43.5

Prior to shipping, the transformer shall be filled with dry nitrogen and positive gas 43.6pressure. A pressure gauge and bleeder shall be fitted to the tank to enable the pressure to be monitored during shipment. A nitrogen supply tank with shutoff valve and pressure regulating valves shall be attached during shipment and shall provide sufficient gas to make up any loss due to leakage.

The dew point of the gas in the tank shall be determined just prior to shipment. 43.7

If the transformer arrives with insufficient positive pressure, then at the option of 43.8SMUD, the windings shall be dried out at the Contractor’s expense.

Two tri-axial impact recorders, which record the severity of the transportation shocks, 43.9will be installed by SMUD or its authorized representative on the transformer tank prior to shipment. Mounting provisions shall be provided on the tank to accommodate these recorders. One impact recorder shall be mounted on a Contractor-furnished shelf that is in accordance with Drawing EDS-E5M-C1012. Mounting locations shall be approved by SMUD before transformer shipment.

The recorders will be in addition to any installed by the transporting company or the 43.10Contractor. The Contractor shall notify SMUD of the shipping date at least two (2) weeks in advance so that arrangements can be made to mount the impact recorders.

The Contractor shall include an annotated master bill of material along with the 43.11shipping manifest with each shipment. An annotation shall be made to the master bill of material indicating date, quantity, and item shipped. This annotated bill of material shall indicate all items shipped and all items remaining to be shipped.

All brackets, adapters, threaded fasteners, and other hardware necessary for complete 43.12field assembly of all transformer equipment shall be supplied.

44. SHIPMENT AND DELIVERY

The Contractor is fully responsible for delivery of the transformer to the foundation 44.1pad designated in the delivery schedule, including assessing site conditions for drayage work.

Land shipment of transformers shall be by truck with air-ride trailer. 44.2

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The Contractor is responsible for coordinating the delivery schedule with SMUD, 44.3

including two (2) week advance notice of arrival and a final 48-hour notice of delivery time.

All parts for each transformer shall be delivered to SMUD’s receiving site on the same 44.4day as the transformer to facilitate unloading. Contractor shall prepare a master bill of materials for all equipment to the supplied with the transformer. The master bill of material shall be provided to SMUD at the time of each material shipment. An annotation shall be made to the master bill of material indicating date, quantity, and items shipped. This annotated bill of material along with the shipping manifest shall be provided to SMUD with each shipment. This annotated bill of material shall indicate all material shipped and all material remaining to be shipped.

Core ground insulation resistance test shall be performed before transformer leaves 44.5truck.

The Contractor shall provide SMUD with the following submittals 4 weeks prior to the 44.6delivery of the transformer to SMUD:

Procedures, drawings, and associated documents required for transporting the 44.7transformer.

Detailed written description of transportation and handling from the manufacturing 44.8facility to SMUD’s project site.

Detailed transportation route, law enforcement/private escort requirements, 44.9transportation permits, and any other permits legally required to move/handle the transformer within the United States, including the State of California, Sacramento County and local Cities within Sacramento County and California.

Detailed work procedures and safety plans, drawings, calculations, and associated 44.10documents for all drayage work to be performed on SMUD’s project site. The drawings shall include plan, end elevation, and side elevation views of the equipment being used and work performed.

The drawings and plans shall indicate the dimensions & weights of the transformer 44.11and all equipment used for the work. The drawings shall include the loads applied to SMUD roads and structures.

The procedures shall include a detailed, chronological narrative of all work to be 44.12performed on SMUD property.

Transportation/lifting/handling equipment technical information, certifications, and 44.13maintenance records shall be provided. All equipment operators shall be currently licensed in accordance with all applicable Federal, State, and Local laws.

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The Contractor shall provide maximum allowable accelerations (3 axes) and 44.14maximum tilt angle to which the transformer can be subjected during transportation and handling without causing damage.

These documents shall be reviewed, stamped, and signed by a Professional Civil or 44.15Structural Engineer currently licensed in the State of California.

The Contractor shall not be allowed to enter SMUD’s facilities or perform work on 44.16SMUD property until the delivery submittals are received and accepted by SMUD.

SMUD will report all shortages, errors, and discrepancies. The Contractor shall 44.17correct these deficiencies in an expeditious manner.

The Contractor shall be responsible for coordination of transformer oil delivery. All 44.18delivery cots shall be paid by the Contractor.

The Contractor shall provide optional pricing to store and maintain the transformer for 44.19up to 12 months beyond the scheduled original delivery date. The pricing shall be provided on a monthly basis. The transformer warranty period shall be considered to commence after completion of transformer assembly/testing following delivery of the transformer to SMUD’s facility.

45. FIELD SERVICES

The Contractor shall be completely responsible for offloading the transformer and 45.1placing the transformer on the foundation.

The Contractor shall be completely responsible for transformer assembly, oil 45.2processing & filling, and testing the transformer as required per SMUD’s TECHNICAL PROCEDURE SP1401 – POWER TRHANSFORMER RECEIPT AND ACCEPTANCE (attached to this specification).

The field services shall be provided in accordance with SMUD’s ENGINEERING 45.3SPECIFICATION S001 – FIELD ENGINEERING SERVICES REQUIREMENTS (attached to this specification) by a technically competent individual who has a minimum of 3 to 5 years of accumulated experience in directing the installation activities of power transformers of similar sizes. The duration of the field services shall be adequate to provide for all installation and startup activities, including: assembly, coordination of oil delivery, vacuum and oil filling, commissioning and testing.

The Contractor shall resolve all installation problems/discrepancies discovered in 45.4design, construction, materials, or workmanship to the complete satisfaction of SMUD.

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46. ATTACHMENTS

The following attachments are a part of these specifications:

ATTACHMENT TITLE

Technical Specification SS1406..….. Electrical Design Review Check List

Technical Specification SS1407..….. Structural Design Review Check List

Technical Specification SS1009....... SMUD’s Equipment Wiring Requirements

Engineering Specification W001...... Drawings and Technical Data

Engineering Specification S001…....

Field Engineering Services Requirements

Technical Procedure SP1401………. Power Transformer Receipt and Acceptance

Drawing EDS-E5M-C1012………….. Transformer Impact Recorder Shelf

Drawing SDS-S3C-A002……………. Fall Protection System Mounting Plate

Drawing EDS-E2B-D001…………….. Schematic, Transformer AC & Alarms

Drawing EDS-E2B-D002…………….. Schematic, Transformer DC & Alarms

Drawing EDS-E2B-D003…………….. Schematic, Transformer Monitor & Control Alarms

Drawing EDS-E2B-D004…………….. Schematic, Transformer LTC Control

Drawing EDS-E2B-D005…………….. Schematic, Transformer LTC

Drawing EDS-E2B-D006…………….. Schematic, Transformer LTC

Drawing EDS-E2B-D007…………….. Outline & Detail, Transformer Air Terminal Chamber

The Contractor shall review all Attachments. Any errors, omissions or deficiencies 46.1shall be brought to SMUD’s attention for resolution.

Qualification Report - The Contractor shall use the report templates as outlined in 46.2latest issue of IEEE 693 Annex S for submittals. The report shall be stamped by a registered State of California Professional Civil or Structural Engineer.

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