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Engineering Specification
Head of Electrical Engineering
MESP 040100 - 01
TECHNICAL SPECIFICATION FOR A SIGNAL
TRANSFORMER FOR USE IN A RAILWAY
SUBSTATION
Version: 1
Issued: October 2015
Owner: Chief Engineer
Approved By:
Andrew Russack
Head of Electrical Engineering
PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION
ELECTRICAL NETWORKS SPECIFICATION
TRANSFORMER FOR USE IN A RAILWAY SUBSTATION
MESP 040100-01
Version: 1 Effective from: 1st October 2015
L1-CHE-SPE-013
Approval
Amendment Record
Approval Date Version Description

Title and Corporate Document number changed previously
01/10/2015 1
L2-ELN-SPE-008, also updated to include oil transformers
Approving Manager: Head of Electrical Engineering Approval Date: 01/10/2015 Next Review Date: 01/10/2018
PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 2 of 15
MESP 040100-01
L1-CHE-SPE-013
Table of Contents
1. Purpose ............................................................................................................................. 4
2. Scope ................................................................................................................................ 4
3. Abbreviations.................................................................................................................... 4
4. Definitions ......................................................................................................................... 4
5. References & Legislation ................................................................................................. 4
5.1 Standards .............................................................................................................................. 4
5.2 Latest Issues and Amendments ............................................................................................ 5
6. Background ...................................................................................................................... 5
7. General Requirements ..................................................................................................... 5
8. Operating Conditions ....................................................................................................... 5
8.1 Service Conditions ................................................................................................................. 5
8.2 Electrical Conditions .............................................................................................................. 5
9. Ratings & Configurations................................................................................................. 6
10. Winding Connection ......................................................................................................... 7
11. Construction ..................................................................................................................... 7
11.1 Transformer Enclosure & Cooling - Dry Type Transformer................................................... 7
11.2 Transformer Cooling and Other Requirements - Oil Type Transformer ................................ 7
11.3 Primary Terminals - Dry type ................................................................................................. 8
11.4 Primary Terminals - Oil insulated type .................................................................................. 8
11.5 Secondary Terminals - Dry Type ........................................................................................... 8
11.6 Secondary Terminals – Oil Insulated Type ........................................................................... 9
11.7 Earthing Terminal .................................................................................................................. 9
11.8 Painting .................................................................................................................................. 9
11.9 Lifting Facility ......................................................................................................................... 9
11.10 Size – Dry Type Transformer ..............................................................................................10
11.11 Rating Plate .........................................................................................................................10
12. Testing ............................................................................................................................ 10
12.1 Type Test .............................................................................................................................10
12.2 Routine Tests ......................................................................................................................10
12.3 Test Certificates ...................................................................................................................10
13. Documentation and Support .......................................................................................... 10
13.1 Documentation Requirements .............................................................................................10
13.2 Design Drawings .................................................................................................................11
13.3 Drawing Format ...................................................................................................................11
13.4 Technical Maintenance Plan ...............................................................................................11
13.5 Maintenance Manual ...........................................................................................................11
13.6 Installation Instruction Manual .............................................................................................12
14. Appendix A – Design Management Requirements ....................................................... 13
15. Appendix B – Technical Data Schedule Form .............................................................. 14
MESP 040100-01
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1. Purpose
This document is the technical specification for a Signal Transformer for use in MTM
substations.
2. Scope
This document applies to the supply of a Power Transformer with a secondary voltage of
2200V phase to phase two wire (unearthed system), 1000V and 650V three phase for use
in a substation installation as part of the MTM Electrical Network.
It may be used to guide the specification of Signal Transformers for renewals at existing
Substations.
3. Abbreviations
ACCB - Alternating Current Circuit Breaker
MTM - Metro Trains Melbourne
HV - High Voltage
4. Definitions
For all technical terms refer to AS 60076.
Shall Is used as the descriptive word to express a requirement that is
mandatory to achieve conformance to the standard.
Should Is used as the descriptive word to express a requirement that is
recommended in order to achieve compliance to the standard.
should can also be used if a requirement is a design goal but not
a mandatory requirement.
5. References & Legislation
5.1 Standards
The Signal Transformer shall comply with all relevant Standards, including:
AS 60076 Power Transformers
AS 1767 - Insulating Liquids Specification for Unused Mineral Insulating Oils for
Transformers & Switchgear.
AS 2374 - Power Transformers.
AS 2735 - Dry-type Power Transformers (if it is a dry-type).
Note: All materials and components shall comply with the relevant Australian Standard or,
where these do not exist, with the relevant IEC or EN Standard.
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5.2 Latest Issues and Amendments

Reference to all standards shall be read as a reference to the latest edition of that standard
and amendments available at the time of tendering.
6. Background
The Signal Transformer is used for the purpose of converting power from the HV supply to
a 2200 phase to phase, 1000V or 650V three phase supply, for Signal and other purposes.
Due to the variable nature of these uses, the following will be specified in a separate
Systems Requirements document:
 Primary Voltage (or equivalent table of ratings to that shown in section 9.1)
 Power Rating
 Indoor or outdoor installation
 Oil insulated or dry type
7. General Requirements
7.1 The Signal Transformer shall be designed and manufactured to give the highest level of
reliability whilst requiring the minimum level of maintenance under continuous operating
conditions.
7.2 The Signal Transformer can be either an oil-insulated or dry type.
8. Operating Conditions
8.1 Service Conditions

8.1.1 The service conditions in AS 60076 shall be applied except that the maximum
ambient temperature shall be taken as 45°C. The air may be slightly polluted by
dust.
8.1.2 Signal Transformers designated for indoor installation will be mounted on a
concrete floor inside a substation building or suitable annex.
8.1.3 Signal Transformers designated for outdoor installation will be mounted on a
concrete slab, unprotected from the weather.
8.2 Electrical Conditions

8.2.1 Supply to the primary winding of the Signal Transformer will be taken via an ACCB
or Fuse Isolator from an HV distribution supply. The HV supply will be either 22kV
or 11kV, 3 phase, 50 Hz. It shall be considered as non-effectively earthed.
8.2.2 The secondary winding will be connected to a switchboard via a suitable circuit
breaker.
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9. Ratings & Configurations

9.1 This specification covers two primary voltages. The specific ratings and characteristics of
each of these are listed in the table below
Type A Type B Type C Type D

Short Description 22kV/2.2kV 11kV/2.2kV 22kV/1kV 22kV/650V
3 Prim / 1
Phases 1 3 1
Sec
Rated Primary Voltage 22kV 11kV 22kV 22kV
Rated Secondary Voltage 2.2kV 2.2kV 1kV 650V
Typical Rated Power 50kVA 50kVA 50kVA 50kVA
Rated Frequency 50Hz 50Hz 50Hz 50Hz
Earthing of secondary Unearthed Unearthed Earthed Unearthed
Primary highest voltage for
24kV 12kV 24kV 24kV
equipment
Secondary highest voltage
3.6kV 3.6kV <1.1kV <1.1kV
for equipment
Primary rated short-duration
power frequency withstand 50kV RMS 28kV RMS 50kV RMS 50kV RMS
voltage
Primary rated lightning
125kV peak 75kV peak 125kV peak 125kV peak
impulse withstand voltage
Secondary rated short-
duration power frequency 10kV RMS 10kV RMS 10kV RMS 10kV RMS
withstand voltage
Secondary rated lightning
20kV peak 20kV peak 20kV peak 20kV peak
impulse withstand voltage
Maximum Sound Power
56dBA 56dBA 56dBA 56dBA
Level
Short-circuit apparent
500MVA 350MVA 500MVA 500MVA
power of the supply system
Special –
Open Delta
Winding Vector N/A Dyn11 N/A
Primary, 30°
phase shift
Regulation @ 0.6 pf ≤4% ≤4% ≤4% ≤4%
9.2 The winding vector may be altered if the reason for it is established and submitted to MTM
for approval.
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10. Winding Connection

10.1 Five output taps on the primary windings shall be provided for the following range: +5.0%;
+2.5%; 0%; -2.5%; -5.0%.
10.2 The selection of the tapping shall be off-load.
10.3 The tap changing device shall have a continuous rating of 100% of the Transformer full load
current.
10.4 Dry Type transformers - The tap position may be selected by moveable connection links
located on each of the primary windings, or by an off-circuit tap changing switch as per
clause 10.5.
10.5 Oil Insulated Type transformers - The tap position shall be selected by a pad lockable,
manually operated selector switch.
10.6 The switch positions shall be labelled, and shall be readable from a distance of 1.2 m.
11. Construction
11.1 Transformer Enclosure & Cooling - Dry Type Transformer

11.1.1 The Transformer shall be enclosed by a ventilated metallic enclosure cooled by
naturally circulated external air. The enclosure should be suitable for indoor or
outdoor installation.
11.1.2 The transformer shall be naturally cooled - it shall be Class AN.
11.1.3 The enclosure shall provide a minimum ingress protection of IP 21 for indoor
installations, or IP 43 for outdoor installations, in accordance with AS 60529
11.2 Transformer Cooling and Other Requirements - Oil Type Transformer

11.2.1 The oil preservation system can be freely breathing or sealed type. The
transformer shall be naturally cooled (ONAN).
11.2.2 The insulating oil shall comply with AS 60076 and shall not contain any
Polychlorinated Biphenyl (PCB).
11.2.3 The oil test for PCB shall be performed by an independent NATA certified
laboratory, and the test results provided to MTM prior to delivery.
11.2.4 A concentration of PCB greater than one part per million will result in rejection of
the transformer.
11.2.5 The transformer shall be equipped with the standard fittings as described below:
• Oil gauge
• Drain valve 25mm nominal bore pipe thread with flanged plug
• Oil filling hole and cap
• Breathing device of weatherproof type, which may also be used as a filling
hole
• Thermometer pocket
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11.2.6 Where a fully sealed transformer is offered the oil gauge and thermometer pocket
need not be included.
11.3 Primary Terminals - Dry type

11.3.1 An accessible air insulated cable box suitable for the connection of an insulated
cable, with dead break elbow connectors to bushing wells, rising from below and
shall comply with IEEE Std 386.
11.3.2 The terminals shall be at least 400mm from the cable entry point to allow for the
length of a typical cable termination.
11.3.3 The terminals shall be suitable for directly connecting to appropriately lugged 50
to 185 mm2 XLPE insulated screened cable.
11.3.4 Appropriate cable supports shall be provided within the enclosure such that the
weight of the input cable is not taken by the electrical connections
11.3.5 Terminals shall be suitably located to accept cables entering the enclosure from
below the transformer, through an appropriate non-ferrous gland.
11.3.6 The air insulated cable box shall be constructed to allow the ready removal and
placement of the dead break elbow connections to the bushing wells.
11.4 Primary Terminals - Oil insulated type

The options for the primary terminals for the oil insulated transformers are provided below.
OPTION DESCRIPTION
Primary An accessible air insulated cable box suitable for the connection of an
Enclosed insulated cable rising from below.
(fixed/bolted lid
cable box)
Primary An accessible air insulated cable box suitable for the connection of an
Enclosed insulated cable, with dead break elbow connectors to bushing wells,
(Hinged door rising from below and shall comply with IEEE Std 386.
cable box)
Primary Open bushing terminals suitable for the satisfactory connection of bare
Exposed copper aerial conductors of 70-100mm2 cross section from above or
horizontal to the Transformer.
11.5 Secondary Terminals - Dry Type

11.5.1 An accessible air insulated cable box suitable for the connection of an insulated
cable, with dead break elbow connectors to bushing wells, rising from below and
shall comply with IEEE Std 386.The terminals shall be suitable for directly
connecting to appropriately terminated LV cables, suitably sized for the rating of
the transformer.
11.5.2 Appropriate cable supports shall be provided within the enclosure such that the
weight of the output cable is not taken by the electrical connections.
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11.5.3 The terminals shall be suitably located to accept cables entering the enclosure
from below the transformer, through an appropriate non-ferrous gland.
11.5.4 The air insulated cable box shall be constructed to allow the ready removal and
placement of the dead break elbow connectors onto the bushing wells.
11.6 Secondary Terminals – Oil Insulated Type

The options for the secondary terminals of an oil insulated transformers are detailed below.
OPTION DESCRIPTION
Secondary An accessible air insulated cable box suitable for the connection of
Enclosed an insulated cable rising from below. The cable will be up to
50mm2 copper insulated cable.
Secondary An open exposed bushing suitable for connection of bare copper
Exposed aerial conductors from above or horizontal.
11.7 Earthing Terminal

11.7.1 The transformer frame shall be directly connected to the substation earth. Two
pre-drilled M12 holes shall be provided on opposite sides of the transformer for
this purpose.
11.7.2 Each enclosure door (where fitted) shall be adequately connected to the main
enclosure by copper earth braids, one located at the top and the other at the
bottom of each door
11.8 Painting
11.8.1 Dry type transformer - The enclosure shall be properly prepared and painted so
as to be suitable for outdoor installation irrespective of the designated installation
location.
11.8.2 Oil Insulated Transformer - The transformers’ external tank shall be properly
prepared and hot dip galvanised.
11.8.3 The final colour coat shall be light grey as described by AS 2700S:2011 (N35),
and shall be supplied with touch-up paint.
11.9 Lifting Facility

11.9.1 The Transformer shall be fitted with a facility for lifting and moving by both a
crane and a forklift.
11.9.2 Suitable lifting lugs shall be provided for lifting by a crane which shall be capable
of lifting the whole weight of the Transformer.
11.9.3 The base shall be fitted with two channel section with minimum dimensions of
100 mm x 50 mm suitable for lifting the Transformer with a forklift.
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11.10 Size – Dry Type Transformer

11.10.1 The transformer and enclosure shall be as compact as possible, and shall occupy
a total floor area no greater than approximately 1300 mm x 1300 mm.
11.10.2 The maximum height of the transformer enclosure shall be 1200mm from the top
of the base channel sections.
11.11 Rating Plate

11.11.1 The Transformer Rating Plate shall comply with the requirements of AS 60076.
11.11.2 The tap link connections and positions or tap changer positions shall be clearly
shown on the rating plate
11.11.3 The rating plate shall be constructed of stainless steel and shall be securely
riveted to the body of the transformer.
11.11.4 Recorded information shall be physically etched, embossed or engraved clearly
onto the surface of the rating plate and shall be highlighted with black paint.
12. Testing
12.1 Type Test

12.1.1 A Type Test Certificate from a design which is representative of the Transformer
to be supplied shall be provided with the Tender documentation.
12.2 Routine Tests

12.2.1 All routine tests as described in Clause 10 of AS 60076.1:2005 shall be
performed on the Transformer at the manufacturer’s factory.
12.2.2 MTM reserves the right to appoint a representative to witness these tests. Seven
working days’ notification shall be given to MTM of intention to carry out factory
testing.
12.3 Test Certificates

12.3.1 The results of all tests shall be recorded on test certificates. The test certificates
shall clearly show the performance of the equipment and shall be accompanied
by tables showing the actually measured values and all calculations.
12.3.2 The test certificates shall be forwarded to MTM and the results approved by MTM
prior to delivery.
13. Documentation and Support
13.1 Documentation Requirements

13.1.1 All documentation shall be provided in English.
13.1.2 One electronic and eight paper copies of the each document shall be provided
and the content shall be identical in each copy.
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13.1.3 Every page of the documentation shall be clearly identified in relation to the
document to which it belongs and the version of that document. All pages of
multi-page documents shall be uniquely numbered. It shall be possible to readily
determine if all pages of a document are present.
13.1.4 Manuals shall be A4 size and shall be bound in durable covers or in 4-D ring
binders.
13.2 Design Drawings

The following drawings must be supplied:
i. Construction details of the Signal Transformer including dimensions.
ii. Physical layout and arrangement of the components of the Transformer.
iii. Mounting requirements for the Transformer.
iv. Physical layout and arrangement of the primary and secondary terminals.
v. Drawings of the Transformer Rating Plate and data
vi. All other drawings required for Installation, Testing, Commissioning, Operation
and Maintenance
13.3 Drawing Format

13.3.1 All drawings must comply with VRIOGS 007.2 - Infrastructure Drafting Standard
and shall be submitted for MTM approval prior to manufacturing.
13.3.2 Files shall be provided in Microstation format on compact disk (CD).
13.4 Technical Maintenance Plan

13.4.1 A Technical Maintenance Plan which establishes the maintenance policy for the
Signal Transformer recommended by the supplier shall be provided. This shall
detail the preventative servicing schedules and maintenance intervals and
latitudes for all components and systems of the Transformer. The servicing
schedules shall reference appropriate detailed instructions in the maintenance
manual.
13.4.2 The Technical Maintenance Plan shall contain a list of any recommended spare
parts, detailing price, supplier and procurement lead-times.
13.4.3 The Technical Maintenance Plan shall detail safe disposal procedures applicable
for when the Signal Transformer is no longer serviceable (recycling, hazardous
waste etc.).
13.5 Maintenance Manual

The Maintenance Manual shall detail:
a) All of the servicing activities.
b) Any overhaul instructions.
c) The adjustment procedures.
d) The changing of components for repairs, and
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e) Fault-finding procedures.
f) Spares support schedule
The Maintenance Manual shall also include a complete set of as-built drawings and a
comprehensive parts list for the Transformer.
13.6 Installation Instruction Manual

13.6.1 An Installation Instruction Manual shall be provided and shall contain instructions
which will enable the Transformer to be properly installed, tested and
commissioned. This shall include all necessary drawings.
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14. Appendix A – Design Management Requirements

This appendix describes the documentation which should be provided as a minimum at
each stage of the procurement process. The documentation shall comply with the
specifications above.
Tender Submission
The following documents shall be provided as part of the tender submission:
General Arrangement drawing of the Signal Transformer which clearly shows:
 The overall dimensions of the Transformer and details of the enclosure
 Details of the proposed primary cable terminations
 Details of the proposed secondary terminations
 Type Test Certificates
 The Technical Data Schedule in Appendix B filled in.
Contract Documentation
One set of PDF copies of the drawings and documentation as described in Clauses 13.2
and 13.6 and any additional documentation detailing the design should be provided for
review and approval by MTM four weeks after the Contact Award Date.
No manufacture shall commence until the drawings have been approved. An allowance of
five working days should be made by the supplier for the review and approval of submitted
drawings
Pre-Delivery Documentation
As part of the deliverables, the supplier shall provide five hard copies of the following
documents:
 Technical Maintenance Plan
 Installation Instruction Manual
 Maintenance Manual
 Storage, handling, loading and off-loading instructions
 Test results
 Approved drawings as listed in 13.2
In addition, the supplier shall provide copies of the As Built layouts and Schematic drawings
in electronic format (PDF and Microstation)
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15. Appendix B – Technical Data Schedule Form

The Tenderer shall supply the following information and guaranteed performance thereof.
Compliance
Does the Transformer fully comply with this specification? Yes  No 
If not provide details of any non-conformance
Is a Type Test Certificate attached? Yes  No 
Is a general arrangement sketch attached? Yes  No 
Type (Dry or oil Insulated)……………………………………………………………………………………
Rated Power
Primary winding (kVA) ………………………
Rated Voltage
Primary windings (V) ………………………
Secondary windings (V) ………………………
Rated Current
Primary windings (A) ………………………
Secondary windings (A) ………………………
Rated Insulation Level
Primary Power Frequency Withstand Voltage (kV) ………………………
Primary Impulse Withstand Voltage (kV) ………………………
Secondary Power Frequency Withstand Voltage (kV) ………………………
Secondary Impulse Withstand Voltage (kV) ………………………
Percentage Impedance at Rated Primary Power
(%) …………………
Regulation @0.6pf ………………………
Losses
Iron Loss (at Rated Primary Voltage) (W) ………………………
Copper Loss (at Rated Primary Current) (W) ………………………
Enclosure – Dry Type
Overall Length (mm) ………………………
Overall Width (mm) ………………………
Overall Depth (mm) ………………………
Enclosure material ………………………
Enclosure thickness (mm) ………………………
Enclosure finish
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Colour ………………………
Weight
Mass of Core and Windings (kg) ………………………
Total mass (kg) ………………………
Tap Changer
Manufacturer ………………………
Type ………………………
Voltage Rating (V) ………………………
Current Rating (A) ………………………
Terminal Details
Primary Terminals
Type ………………………
Height above base of enclosure (mm) ………………………
Secondary Terminals
Type ………………………
Height above base of enclosure (mm) ………………………
Cable Box dimensions - (if applicable)
Height…………………………………………..……..………….mm
Width…………………………………..……………….…………mm
Depth……………………………………………………...………mm
Volume of Oil ………………………………………………………………………………………..……Litre
Is the Transformer freely breathing?...............................................................................................Y/N
Is a Conservator fitted? …………………………………………………………………..………….…...Y/N
.Is the Transformer a sealed-tank system with gas cushion?..…………………………….…..…..…Y/N
Is the Transformer a sealed, completely filled system? ..……………………………………..……...Y/N
Tank or Enclosure Thickness ………………………………………………………………………..…..mm

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Engineering Specification

Head of Electrical Engineering

Issued: October 2015

Owner: Chief Engineer

Head of Electrical Engineering

Approval Date Version Description

5. References & Legislation

5.2 Latest Issues and Amendments

8.1 Service Conditions

8.2 Electrical Conditions

9. Ratings & Configurations

Type A Type B Type C Type D

10. Winding Connection

11.1 Transformer Enclosure & Cooling - Dry Type Transformer

11.2 Transformer Cooling and Other Requirements - Oil Type Transformer

11.3 Primary Terminals - Dry type

11.4 Primary Terminals - Oil insulated type

11.5 Secondary Terminals - Dry Type

11.6 Secondary Terminals – Oil Insulated Type

11.7 Earthing Terminal

11.9 Lifting Facility

11.10 Size – Dry Type Transformer

11.11 Rating Plate

12.1 Type Test

12.2 Routine Tests

12.3 Test Certificates

13. Documentation and Support

13.1 Documentation Requirements

13.2 Design Drawings

13.3 Drawing Format

13.4 Technical Maintenance Plan

13.5 Maintenance Manual

13.6 Installation Instruction Manual

14. Appendix A – Design Management Requirements

15. Appendix B – Technical Data Schedule Form

Is a Type Test Certificate attached? Yes  No 

Is a general arrangement sketch attached? Yes  No 

Type (Dry or oil Insulated)……………………………………………………………………………………

Cable Box dimensions - (if applicable)

Volume of Oil ………………………………………………………………………………………..……Litre

Is the Transformer freely breathing?...............................................................................................Y/N

Is a Conservator fitted? …………………………………………………………………..………….…...Y/N

.Is the Transformer a sealed-tank system with gas cushion?..…………………………….…..…..…Y/N

Is the Transformer a sealed, completely filled system? ..……………………………………..……...Y/N

Tank or Enclosure Thickness ………………………………………………………………………..…..mm

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