0 E

21,NOV,12 06,NOV,12

FOR CONSTRUCTION FOR REVIEW

FOR CONSTRUCTION REFLECT COMMENT

S.Y.KIM S.Y.KIM

T.W.KIM T.W.KIM

T.M.KWON T.M.KWON

14,May,12

FOR REVIEW

REFLECT COMMENT

M.S.SEO

T.W.KIM

T.M.KWON

Revised Lightning C 19 MAR 12

th

FOR REVIEW

Impulse Test acceptance criteria

M.S.SEO

T.W.KIM

T.M.KWON

B REV.

12 ,JAN,12 DATE

th

FOR REVIEW STATUS

REFLECT COMMENT DESCRIPTION

M.S.SEO PREPARED BY

T.W.KIM CHECKED BY

T.M.KWON APPROVED BY

Owner

RABIGH POWER PLANT NO.2 PROJECT UNITS # 01, 02, 03 & 04 Contract # 31021001/00
OWNERS ENGINEER

MAIN CONTRACTOR

SUB CONTRACTOR

DOCUMENT TITLE

NAME PREPARED BY CHECKED BY APPROVED BY S.Y.KIM T.W.KIM T.M.KWON

DATE
21, NOV,12 21, NOV,12 21, NOV,12

Inspection Procedure for Unit Transformer

(Reference document : HHI-ITP-11-103 page 6~13)

DOCUMENT NO.

Approval/Certification Information Doc No.: PB-10195 Rev.: v1 No. of Pages 13 Rev. No. 0

31021001/00-Z-RPP2-WE001308
DOCUMENT STATUS:

FOR INFORMATION FOR APPROVAL FOR REVIEW FOR CONSTRUCTION AS BUILT

RABIGH POWER PLANT No.2 Inspection Procedure for Unit Transformer

Doc.No Page Z-RPP2-WE-001308 2 of 13 Rev 0

Table of Content

1. Unit Transformer Test Procedure

(Ref. Hyundai Inspection and Test Procedure II Page 6 ~ Page 13)

3~ 10

2. SEC recommendation method 3. Addenda for type and routine test

11~12 13

RABIGH POWER PLANT No.2

Inspection Procedure for Unit Transformer

No. 1. INSPECTION & TEST ITEMS Visual inspection(Ro) DESCRIPTION 1. Construction, painting & welding condition will be inspected visually. 2. Dimension will be measured in accordance with the approved specification. 1. The winding resistance will be measured by the DC voltage drop method with resistance measuring system. 2. This test shall be made on all windings and all tap positions. 3. Test results shall be corrected to 75 values. 4. This test shall be repeated at the end of tests. 5. DC current : Max. 100A

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PASS / ACCEPTANCE CRITERIA * The inspection results shall be satisfied with approved specification and drawings.

2.

Winding resistance measurement(Ro)

3.

Ratio check(Ro)

1. The voltage ratio shall be measured by means of transformer turns ratio(TTR) test set and on single phase, phase by phase. 2. The applied voltage to HV winding will be about 120(V). 3. The test shall be made on all windings and all tap positions. 1. The phase relationship shall be checked at rated voltage tap connection. 2. Three phase 220(V) will be applied to HV winding and the voltage shall be measured between terminals. 3. Vector diagram will be drawn and confirmed. 1. The test shall be made between HV and LV1 winding, HV and LV2 winding, LV1and LV2 winding, HV winding and earth, LV1winding and earth, LV2 winding and earth with 5000(V) megger tester. 2. The test shall be made on 15Sec,1min. and 10 minutes. 3. Core to earth, clamp to earth, core+clamp to earth for one minute with 3500V megger. 1. The test shall be made each winding to ground and between the windings with Doble tester. 2. IEEE C57.12.90 table 4 method II is prefered. 3. Test voltage shall be from 2kV to 12kV in steps of 2kV.

* Ratio error shall be within 0.5% at all tappings.

4.

Phase relationship check(Ro)

* Phase relationship Dyn7yn7

5.

Insulation resistance measurement(Ro) (Including core insulation test)

* PI : Min. 1.3

6.

Insulation power factor and capacitance measurement(Ro) (Before and after dielectic tests)

* P.F : max. 0.5% at 20

RABIGH POWER PLANT No.2

Inspection Procedure for Unit Transformer

No. 7 INSPECTION & TEST ITEMS Insulation power factor and capacitance measurement of capacitor bushing(Ro) DESCRIPTION 1. Capacitance C1 and tan delta of condenser bushings in voltage range of 0 to 12kV in step of 2kV shall be measured on each capacitor bushings. 2. The bushings with tan delta > 0.4% at < 30 shall be rejected. 3. Capacitance C2 and tan delta shall be measured at 0.5 & 1.0 Kv. 4. The tests on bushings shall be performed separately from transformer. C1: 10kV, C2: 0.5kV 1. The test shall be made at 70%, 90%,100%,110% & 120% of rated voltage and rated frequency.(60Hz) Tap pos. : rated tap 2. The test voltage shall be applied to a LV winding with the other winding left open circuited. 3. The loss will be measured by three wattmeter method. 4. After the completion of the dielectric test the excitation losses shall be measured at 100% rated voltage. The excitation voltage shall then be increased to 110% rated voltage and the transformer left excited for 1 hour. The voltage shall then be reduced to 100% of rated voltage and excitation losses measurements repeated. 5. Measurement of harmonics of no-load current at 100%, 110% and 120% rated voltage. 6. 1,2,3,5,7,9,11th and 13th harmonic content shall be measured using harmonic analyzer and expressed as percentage of 60Hz component. 1. The transformer shall be energized at rated voltage and frequency with no load. 2. The microphone shall be located at 1mt interval and spaced 0.3m(ONAN base) from datum level. 3. The frequency spectra of the audible sound pressure shall be measured at factory. 4. The background noise level before and after test shall be measured.

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PASS / ACCEPTANCE CRITERIA

No-load loss & current measurement(Ro)

Before and after dielectric tests

* No-load loss & excitation current No-load loss Excit. Current(%) 70% 79KW 0.24% 100% 120KW 2.40% 110% 120KW 2.40% 120% * Tolerance of excitation current : +30%

(Measurement of harmonic contents)(S)

Sound level measurement(S)

* Sound Pressure level 76 dB(A) at ONAN base,0.3meter

RABIGH POWER PLANT No.2

Inspection Procedure for Unit Transformer

No. 10 INSPECTION & TEST ITEMS Impedance voltage & load-loss measurement(Ro) DESCRIPTION 1. The test shall be made at rated frequency and current by short circuit method. 2. The test shall be made on the principal, highest and lowest voltage tap positions at 1.0Pu, 1.1Pu and 1.3Pu load current base on Max. rating( HV-LV1, HV-LV2). But the test of LV1-LV2 will be carried out at low capacity and the rusults will be corrected to 1.0PU and 1.3PU. The test to be performed at all other taps at 0.5Pu.( HV-LV1 & HV-LV2 ) 3. The load loss and impedance voltage will be measured on Max. rating base and corrected to the other ratings. 4. Symmetric loading(load balance) should be checked at extreme taps and principal tap base on Max. rating, and the results to be included at final test report. 5. The measured load loss and impedance voltage shall be corrected to the reference temperature of 75. 1. The test shall be made at the maximum loss tap with the rated frequency by short circuit method. 2. At first, to determine the top oil and the average oil temperature rise, the test losses shall be supplied as follow; Test losses ( Total loss ) = Load loss + No Load loss 3. After saturation, input shall be then reduced to rated current and this current is maintained for 1 hour. 4. After shut down the electric power, the temperature of winding is determined by the resistance method. Resistance measurement shall be made first on the highest temperature winding, then other windings. 5. The sequence of test shall be as follows (HV-LV1+LV2) ; a) 100% ONAN and 100% ONAN cooling without spare 110% ONAN and 100% ONAN cooling with spare cooler. b) 130% ONAN and 100% ONAN cooling without spare cooler for 4hours preceeding load of 1.0pu continues. 6. Thermograpic infra-red scanning of transformer tank walls,

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PASS / ACCEPTANCE CRITERIA * % imped. and load loss at 75, principal tap Load loss % Imp.(60MVA) HV-LV1:16.0% 185KW HV-LV1, 60MVA HV-LV2:16.0% 185KW HV-LV2, 60MVA 370KW HV-(LV1+LV2), 120MVA HV-(LV1+LV2) of %imp. (120MVA, 75) : 18% Tol of %imp. : +7.5% * refer to data sheet for other %imp values.

11

Temperature rise test(T) (Before dielectric tests)

* Oil temperature rise : 40 * Winding temperature rise : 45 * Hot spot temperature rise : 48 At end of overload, The following hot spot temp. shall not be exceed. Base on Max. ambient temp. of 50. * Top oil temp. : 115 * Winding hot spot temp./metalic parts : <140 at 50 amb. * Oil exponent X=0.8 at ON cooling Winding exponent Y=1.3 at ON and OF cooling. Hotspot factor H=1.3

RABIGH POWER PLANT No.2

Inspection Procedure for Unit Transformer

No. INSPECTION & TEST ITEMS DESCRIPTION bushing turrets and covers shall be performed during over-load temperature rise test. 7. Following data shall be recorded/calculated; a) bushing stud temperatures at the end of over-load heat run. b) average oil time constant c) winding time constant 1. The test will be made according to IEC:60076-3, clause 13,14 if not specified in this procedure. 2. Polarity of test voltage : Positive 3. The test shall be carried out with OLTC on SW. POS. 1, 11 and 21 with each of the three phases being tested for LI. During neutral test, tap position should be minimum volt. 4. Test sequence HV, LV1, LV2 winding : R.FW-FW-R.CW-CW-CW-FW-FW Neutral : R.FW - FW - FW - FW Where R.FW is the reduced full wave, FW is full wave, R.CW is reduced chopped wave, CW is chopped wave. 5. Standard voltage wave form(Front/Tail time) Full wave : 1.230% / 5020% Chopped wave : 2 6 Neutral : front time up to 13 6. Impulse current traces, with a sweep time of 10 to 25us shall be recorded. 7. The required crest voltage for LI shall be increased if the actual front time exceeds 2.0us or the actual time to 50% crest value is less than 40us according to correction factor table in the SEC spec. 8. Recording shall be of minimum three independent channels for LI. 9. Test voltage(LI) 1) HV winding : 250kV 2) LV1 and LV2 winding : 125kV 3) LV Neutral : 125kV

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PASS / ACCEPTANCE CRITERIA

12.

Impulse tests(Ro) (Just after temp. rise test, hot condition) Lightning impulse test

* To be withstood

Dielectric test sequence lightning impulse--> neutral lightning --> separate source AC -->ACSD--> ACLD--> capacitance&tan delta

RABIGH POWER PLANT No.2

Inspection Procedure for Unit Transformer

No. 13 INSPECTION & TEST ITEMS Separate-source AC voltage withstand test(Ro) DESCRIPTION 1. Test voltage at rated frequency must be adjusted using peak volt meter. 2. The single phase AC voltage shall be applied to each winding with other winding and tank solidly grounded. 3. Test frequency and duration : 60 Hz / 60sec 4. Test voltage 1) HV winding to earth : 95kV 2) LV1 winding and neutral to earth : 50kV 3) LV2 winding and neutral to earth : 50kV 1. The transformer shall be excited with high frequency power source to prevent from saturation of magnetizing flux. 2. Test frequency : 180Hz or 240Hz 3. Test duration : 60Sec 4. Test voltage : 50KV at HV (Two times of Um)

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PASS / ACCEPTANCE CRITERIA * To be withstood

14

Induced overvoltage withstand test(Ro)

* To be withstood

15

Zero-sequence impedance measurement(S)

1. The test shall be made at rated frequency between the line terminals and the neutral. 2. The zero sequence impedance shall be measured on the rated and extrem tap positions. 3. Sketch showing the magnetic core and the disposition of windings shall be enclosed with the report. 4. The measuring current must not be higher than 30% of the nominal current. 1. Single phase voltage 220380V 60Hz be applied to each phase of HV or LV1 or LV2 line terminals by turn and voltage induced in the other phases are to be measured. 1. Operation test With the tap changer fully assembled on the transformer, following sequence of operations shall be performed without failure; a) with transformer un-energized, 8 complete cycles of operation at no load, 1 complete cycle of operation. b) with transformer un-energized, and with the auxiliary voltage reduced to 85% of its rated * Not to be abnormal condition

16

Magnetic balance test(Ro)

17

Test of on-load tap changer(Ro)

RABIGH POWER PLANT No.2

Inspection Procedure for Unit Transformer

No. INSPECTION & TEST ITEMS DESCRIPTION value, 1 complete cycle of operation. c) with transformer energized at rated voltage and frequency at no load, 1 complete cycle of operation. d) with one winding short-circuited and, as far as practicable, rated current in the tapped winding, 10 tap-change operations across the range of two steps on each side from where a coarse or reversing changeover selector operates, or otherwise from the middle tapping. 2. Power frequency withstand test shall be carried out on auxiliary devices with 2000V AC for 1 min. 1. Completely assembled transformer shall be subjected to a pressure corresponding to twice the normal head of oil or the normal oil column + 0.5kg/cm2 whichever is higher, for 12hrs. There shall be no leak or sweating by visual. 2. The transformer tank, conservator, coolers shall be subjected to a pressure. 1. Sequence test shall be performed according to approved drawings. 2. The voltage to ground shall be 2500Vrms for equipment rated up to 250Vdc and 1500Vrms for other voltage ratings. Test voltage across open contacts shall be 1500Vrms for contacts rated for tripping and 1000V for contact not rated for tripping.(for 1 minute with all the circuits tied together) 3. Insulation resistance shall be measured with 500(V) megger tester(Include C.T). temperature indicators, fans and others shall be subjected to an operational test to assure the proper coordinated functioning. 1. Ratio and polarity test of BCT shall be carried out before installation on transformer. 2. Ratio error shall be measured between primary and secondary winding with BCT test system. 3. Polarity test shall be made by inductive kick

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PASS / ACCEPTANCE CRITERIA

18

Oil leakage and pressure test(Ro) (In-process stage test before FAT)

* No leakage is allowed. * Tank permanent Deformation : 1mm

19

Control panel & Auxiliary equipment check(Ro)

* The inspection results shall be satisfied with approved specification and drawings.

20

Bushing C.T test(Ro)

Routine tests with IEC 60044-1 and test report shall be submitted. 1. Polarity test 2. Insulation resistance 3. Powerfrequency test 4. Inter-turn overvoltage test 5. current error and phase displacement 6. secondary winding resistance

RABIGH POWER PLANT No.2

Inspection Procedure for Unit Transformer

No. INSPECTION & TEST ITEMS DESCRIPTION method with DC voltage source. 4. The magnetization tests of bushing C.T for protective relay shall be taken before assembly in the transformer tank and to be shown. 5. The C.T secondary winding resistance measurements shall be performed on with the bridge method. Oil samples shall be taken before and after for gas-in-oil analysis as following stages; 1) All tests 2) 1 hr 110% excitation test. 3) Temperature rise test 4) Overload test 5) After 612hrs after shut down 6) After complete tests. Certificate of vacuum test of the tank shall be submitted with final report. (Test duration : 6hrs) (Full vacuum, less than 1 torr for tank, cooler, conservator and tap changer) Before and after transformer tests, We will check dielectric strength, moisture content, particle contents(IEC 60970) in transformer oil. 1. The test shall be made at 100% and 110% of rated voltage and rated frequency under full assembly condition. 2. Vibration value shall be checked on the tank wall.

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PASS / ACCEPTANCE CRITERIA

21

Dissolved gas-in-oil analysis(Ro)

22

Vacuum test(Ro) (In-process stage before final acceptance test)

* Tank permanent Deformation : 1mm

23

Mineral insulation oil test(Ro)

* Review of test reports. Break down volt.(IEC 60156) : 70kV, Water content (IEC 60814) : <10ppm * Shall not exceed 60 microns at any point of the main tank.

24

Vibration test(S)

25

SFRA test(Ro)

1. SFRA(10 ~ 2) shall be preformed on each transformer. 2. Test equipment : Doble M5100 or M5200 3. Test method : Doble recommended method or SEC Recommended method(refer to the attached SFRA test) 4. Test tap : pincipal tap and Max. voltage tap 5. Test condition : with oil and bushings 6. Open circuit tests : H1-H2, H2-H3, H3-H1, X1-X0, X2-X0, X3-X0

RABIGH POWER PLANT No.2

Inspection Procedure for Unit Transformer

No. INSPECTION & TEST ITEMS DESCRIPTION 7. Short circuit tests X1-X2-X3 shorted together ; H1-H2, H2-H3, H3-H1 Y1-Y2-Y3 shorted together ; H1-H2, H2-H3, H3-H1, X1-X0, X2-X0, X3-X0 1.Short circuit impedance per phase basis, between each pair of winding from the HV as well as LV, LV1 & LV2 side. Measurement shall be performed for all tappings position at HV - LV1, HV - LV2, HV - LV1+LV2 conditions. 2. Test voltage : 380V5000V, 60HZ Single phase low voltage 220380V, 60Hz shall be applied to each phase of HV, LV terminal by turn and the magnetizing current is measured at max. volt. tap position. (after core demagnetizing) Tests on bushings will be carried out at bushing manufacturer. The test reports will be submitted for review. This test will be carried out after core and coil assembly but before in-tanking. The type of instruments and combination of tests, will be submitted for approval. According to SEC recommended method(refer to the attached SFRA)

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PASS / ACCEPTANCE CRITERIA

26

Measurement of single phase low voltage impedance, 60Hz(Ro)

27

Measurement of single phase excitation current at low voltage 60Hz(Ro)

28

Tests on Bushing(Ro)

29

Measurement of transient voltage transfer characteristic(S)

Ro : Routine test T : Type test S : Special test

Type & special test to be carried out on one unit only of the same type. Routine test to be carried out for all units.

RABIGH POWER PLANT No.2

Inspection Procedure for Unit Transformer

Attachment - SFRA

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SEC

MVA Sweep Frequency Response Analysis test table

(Tap No. : 1/11/-, Frequency : 10Hz ~ 2MHz)

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Phase 1U-1N 1V-1N 1W-1N 1U-2U 1V-2V 1W-2W 1U-3U 1V-3V 1W-3W 1U-2U (1N, 2V : Ground) 1V-2V (1N, 2W : Ground) 1W-2W (1N, 2U : Ground) 1U-3U (1N, 3V : Ground) 1V-3V (1N, 3W : Ground) 1W-3W (1N, 3U : Ground) 1U-1N (2U-2V : Short) 1V-1N (2V-2W : Short) 1W-1N (2W-2U : Short) 1U-1N (3U-3V : Short) 1V-1N (3V-3W : Short) 1W-1N (3W-3U : Short) 1U-1N (2U-2V, 3U-3V : Short) 1V-1N (2V-2W, 3V-3W : Short) 1W-1N (2W-2U, 3W-3U : Short)

connection

11

11

open

Inter winding

Inductive Inter winding

Short

RABIGH POWER PLANT No.2

Inspection Procedure for Unit Transformer

Attachment -Transient Voltage Test

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MEASUREMENT OF TRANSIENT VOLTAGE TRANSFER CHARACTERIST

CH2 1U CH1 (+ Polarity)
CH5 CH6

2U

1W

1V

2W
CH4 CH7 CH3

2V

Fig. 1 The LV terminals are open

1U CH1 (+ Polarity) C

2U CH2

CH6 CH5 CH7

1W

1V

2W

2V

This test will be carried out at A, B and C phase

with same method.

CH4

CH3

Fig. 2 Each LV terminals si earthed through a CF capacitor

RABIGH POWER PLANT No.2

Inspection Procedure for Unit Transformer

addenda for type and routine test Type Test Special Test Inspection Process Temperature rise test(T) (Including over-load test) Sound level measurement(S) Measurement of transient voltage transfer characteristic.(S) - In-process test Zero-sequence impedance measurement(S) Vibration test(S) Visual inspection(Ro) Winding resistance measurement(Ro) Ratio check(Ro) Phase relationship check(Ro) Insulation resistance measurement(Ro) (Including core insulation test) Insulation power factor and capacitance measurement of transformer (Ro) Insulation power factor and capacitance measurement of capacitance bushings (Ro) No-load loss & current measurement(Ro) (Including harmonics measurement(S)) Impedance voltage and load loss measurement(Ro) Lightning impulse test(Ro) Separate-source voltage withstand test(Ro) Induced overvoltage withstand test(Ro) Magnetic balance test(Ro) Test of on-load tap changer(Ro) Oil leakage and pressure test(Ro) - In-process test Control panel & Auxiliary equipment check(Ro) Bushing C.T test(Ro) Dissolved gas-in-oil analysis(Ro) Vacuum test(Ro) - In-process test Mineral insulation oil test(Ro) SFRA test(Ro) Measurement of single phase low voltage impedance(Ro) Measurement of single phase excitation current(Ro) Tests on bushings(Ro)

Doc :WE-001308 Applicable Code IEC 60076-2(2000) IEC 551(1987) MFR Standard IEC 60076-1(2000) Clause 10.7 MFR Standard Approved drawings IEC 60076-1(2000) Clause 10.2 IEC 60076-1(2000) Clause 10.3 IEC 60076-1(2000) Clause 10.3 IEEE C57.12.90, 2006 CL 10.11 IEC 60076-1(2000) Clause 10.1.3,i) IEC 60076-1(2000) Clause 10.1.3,i) IEC 60076-1(2000) Clause 10.5 IEC 60076-1(2000) IEC 60076-3(2000) Clause 13.14 IEC 60076-3(2000) Clause 11 IEC 60076-3(2000) Clause 12 MFR Standard IEC 60076-1(2000) Clause 10.8 MFR Standard Approved drawings IEC 44-1(1996) IEC 44-1(1996) MFR Standard IEC 60296 (2003) MFR Standard MFR Standard MFR Standard IEC 137

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Routine Test