NUMBER E04-S01

REV. NO. 1
ENGINEERING STANDARD DATE MAR 2004
PAGE 1 OF 19

Oil-Immersed Power Transformers (NEC)

This document is issued by Engineering Standards Section, SABIC Engineering and Project Management, Kingdom of Saudi Arabia.
The information contained in this document is the confidential property of SABIC. It can not be disclosed, copied or used for any purpose
without prior approval from SABIC. If you are not authorized to posses this document, please destroy it immediately.
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CONTENTS

1. SCOPE........................................................ 3 7. INSULATION SYSTEM 15

2. REFERENCES 3 7.1 Turn Insulation ......................................15
3. DEFINITIONS 3 7.2 Insulation Life 15
4. GENERAL ................................................... 3 7.3 Liquid Insulating System 15
5. DESIGN REQUIREMENTS 3 7.4 Liquid Preservation System..................15
5.1 Service Conditions 3 8. TESTS 15
5.2 Winding, Temperature Rise / 8.1 Standard Tests 15
Ratings, Impedance ............................... 4 8.2 High Potential Test................................16
5.3 Core and Coil Construction 5 8.3 Miscellaneous Tests on Insulating
5.4 Efficiency and Loss Penalty 5 Liquid 16
5.5 Bushings ................................................ 6 8.4 Certification 16
5.6 Tank and Enclosure 6 9. LIFTING, MOVING, AND JACKING
5.7 Cooling 7 FACILITIES................................................16
5.8 Terminal Chambers, External 10. DOCUMENTATION 16
Clearances, and Space Heaters ............ 7 11. SHIPPING 17
5.9 Accessories 8 12. ERECTION ASSISTANCE.........................18
5.10 Hardware 10
5.11 Alarm and Control Devices .................. 10 FIGURE
5.12 Wiring and Control Cabinet 10 1 Description of Operation 18
5.13 Audible Sound Levels 11 2 Voltage Drop Through a Typical
5.14 Coatings ............................................... 12 Transformer 19
5.15 Manual Tap Changer 12
5.16 On Load Tap Changer 13 TABLE
5.17 Short Circuit ......................................... 13 I Distribution Levels for Transformers
5.18 Basic Impulse Insulation Level (BIL) 14 Below 2500 kVA ........................................14
5.19 Lightning Arresters 14 II Power Levels 14
5.20 Harmonics ............................................ 14
6. CAPTIVE TRANSFORMERS 14
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1. Scope
This specification provides requirements for design, manufacture, testing, and shipping of three-phase,
two-winding, oil-immersed, air-cooled power transformers with a rating of 500 kVA and above with a
nominal voltage rating of 230 kV and below.

2. References
Reference is made in this specification to the following documents. The latest issues, amendments, and
supplements to these documents shall apply unless otherwise indicated.
SABIC Engineering Standards (SES)
E02-G01 Electrical System Design Criteria
E11-S01 Low Resistance Grounding System
E11-S02 High Resistance Grounding System
E11-S03 Bonding and Grounding
Q01-G02 General Surface Preparation and External Painting of Equipment
American National Standards Association (ANSI)
C57.12.00 Standard General Requirements for Liquid Immersed Distribution, Power, and Regulating
Transformers
C57.12.10 Safety Requirements 230 kV and Below, 833/958 Through 8333/10, 417 kVA, Single-Phase,
and 750/862 Through 60,000/80,000/100,000 kVA, Three-Phase Without Load Tap Changing; and
3750/4687 Through 60,000/80,000/100,000 kVA With Load Tap Changing
C57.12.80 Standard Terminology for Power Distribution Transformers
C57.12.90 Standard Test Code for Liquid-Immersed Distribution, Power, and Regulating Transformers;
and Guide for Short-Circuit Testing of Distribution and Power Transformers
C57.13 Standard Requirements for Instrument Transformers
C57.104 Guide for the Interpretation of Gases Generated in Oil-Immersed Transformers
American Society for Testing and Materials (ASTM)
B 117 Test Method of Salt Spray (Fog) Testing
D 714 Standard Method for Evaluating Degree of Blistering of Paint
D 1535 Method for Specifying Color by the Munsell System
D 1654 Method for Evaluation of Painted or Coated Specimens Subjected to Corrosive Environments
D 3487 Specification for Mineral Insulating Oil Used in Electrical Apparatus

3. Definitions
See ANSI C57.12.00 for definitions for terms used in this specification.

4. General
4.1 Data sheets SES E04-X01 and the following standards shall be used in conjunction with this
specification: SES E02-G01, E11-S01, E11-S02, E11-S03 and ANSI C57.12.80.
4.2 Any conflict(s) between this specification, SES and industry standards, engineering drawings, and
contract documents shall be resolved at the discretion of SABIC.

5. Design Requirements
5.1 Service Conditions
5.1.1 Transformers shall be designed to operate at specified load continuously and intermittently.
5.1.2 Transformers shall be designed to operate outdoors in an atmosphere typical of industrial facilities
and petrochemical plants located in coastal and desert areas with very fine blown dust conditions.
5.1.3 Transformers and their accessories shall be designed to operate in an ambient temperature of 1 qC
to 50 qC with metallic surface temperatures reaching 75 qC due to solar radiation.
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5.1.4 Transformers shall be designed for an ambient air design temperature for any 24 hour period, of
50 qC.
5.1.5 Maximum design altitude shall be 1000 m unless otherwise shown on the data sheet.
5.1.6 Relative humidity is 0 to 95 percent noncondensing.
5.1.7 Seismic condition, UBC Zone 1, unless otherwise specified on data sheet.
5.2 Winding, Temperature Rise / Ratings, Impedance
5.2.1 Unless otherwise specified, primary and secondary windings shall be made of electrical grade
copper with a minimum conductivity of 98 percent International Annealed Copper Standard (IACS) for
copper used in electrical conductors. The conductors shall be machine spirally wound with several
overlapping layers of insulation paper. This process shall detect and eliminate conductor burrs that might
affect the dielectric integrity of the winding.
5.2.2 Permanent current carrying joints, except threaded connections and compression joints, shall be
welded or soldered with silver solder or silver alloy having a melting point of 590 qC or above. Bolted or
clamp type connections may be used at bushings, tap changers and terminal boards providing that suitable
locking devices are used to prevent the connections from becoming loose.
5.2.3 Leads from the windings to the terminal boards and bushings shall be rigidly supported to prevent
damage from vibration. Guide tubes shall be used wherever possible.
5.2.4 Coil windings shall be given not more than one dip treatment of varnish which shall be applied for
mechanical protection and not for improvement in dielectric properties. However, in no case shall varnish
or other adhesive be used which will seal the coil and prevent evacuation of air and moisture, and
impregnation by oil.
5.2.5 Transformer and accessories shall be designed to provide the specified self-cooled (OA) rating, with
a winding temperature rise by resistance of not more than 55 qC at nominal kVA rating.
5.2.6 Transformer and accessories shall be able to operate continuously with an average winding
temperature rise of 55 qC above ambient when operated at forced air-cooled (FA) rating.
5.2.7 Forced air-cooled (FA) kVA rating of transformer shall conform to Table 12 of ANSI C57.12.10. kVA
rating shall be continuous at a winding temperature rise of 55 qC or 65 qC and shall be based on not
exceeding the specified average winding temperature.
5.2.8 The guidelines provided in Table 12 of ANSI C57.12.10 for FA rating are given below:
500-2000 kVA : 1.15 x OA rating at specific winding temperature rise above ambient
2,500-10,000 kVA : 1.25 x OA rating at specific winding temperature rise above ambient
5.2.9 For transformers using two stages of forced air cooling, that is OA/FA/FA the increase in rating may
vary between manufacturers. Transformers above 10,000 kVA shall be built in accordance with
ANSI C57.12.10, where 1 represents the OA rating at 55 qC rise.
5.2.10 Average winding temperature rise above ambient shall not exceed 55 qC when measured by
resistance and the winding hottest spot temperature shall not exceed 65 qC above ambient. Temperature
rise shall be determined in accordance with ANSI C57.12.00, section 5.11.2. If temperature detectors are
specified, temperature rise shall be measured by winding temperature detectors.
5.2.11 Temperature rise of the insulating liquid at Class OA rating and measured near the top of the tank
shall not exceed the average winding temperature rise above ambient.
5.2.12 Temperature of metallic parts in contact with the insulation of current carrying conductors shall not
exceed the winding hottest spot temperature rise.
5.2.13 Temperature gradient from the winding hottest spot to the top of the insulating liquid shall be
provided with the test data.
5.2.14 Unless otherwise specified on the data sheet, standard percent impedance voltages shall conform
to ANSI C57.12.10, Table 10.
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5.2.15 Impedance voltage shall be referred to at temperature 70 qC. This is the sum of the rated average
winding temperature rise by resistance (50 °C) plus 20 °C.
5.2.16 All switches and devices, except tap changers, required to be operated or tested shall be located
at a maximum height of 1.5 m above the transformer base. Devices mounted above this height shall be
legible from grade.
5.2.17 Unless otherwise specified on the data sheet, primary winding shall be delta-connected and
secondary winding shall be wye-connected. The angular displacement between the primary and
secondary phase voltages shall be 30q with the secondary lagging the primary. Neutral shall be brought
out through a bushing. The angular displacement shall be in accordance with ANSI C57.12.00,
Section 5.7.2.
5.3 Core and Coil Construction
5.3.1 The core shall be of high quality grain oriented, non-aging electrical silicon steel having low
hysteresis loss and high permeability. The core legs shall be securely held by means of through bolts
insulated with not less than Class B insulation, or glass cloth tape, or SABIC approved equal, with
adequate padding adjacent to the iron, or be encased in a strong fiber tube and securely wedged within
the tube. The use of organic tape or pressed board wrapping to hold the laminations is not acceptable.
5.3.2 Industry designations for electrical grade core steel are as follows:
a. Grade H1 - Laser scribed super grain oriented steel. This grade is used where core losses are at
a premium and is often used by electrical utilities.
b. Grade M6 - Straight grain oriented steel. This grade has higher core losses than H1 and is
normally used in distribution service at industrial locations.
5.3.3 The core laminations shall be free of burrs and sharp projections. Each sheet shall have an
insulating coating resistant to the action of hot oil.
5.3.4 The completed core and coil assembly shall be assembled and braced in a way that the center line
and the outside surface of the coil stack shall lie in a vertical plane. The deviation of this plane from the
vertical shall be kept to a minimum.
5.3.5 The core shall be tightly clamped, the coils shall be securely fixed to the core and the core and coils
shall be rigidly fixed in the tank to prevent movement under short circuit stresses and while handling during
shipment. The structure shall be securely grounded to prevent electrostatic potentials. This ground shall
be brought to the outside through an insulating bushing, to be easily accessible for checking the core in
the field with a megger type meter for unintentional grounds. The ground point shall be clearly and
permanently labeled.
5.3.6 Electrical conductors shall be electrolytic copper, conductivity 98 percent IACS.
5.4 Efficiency and Loss Penalty
5.4.1 Unless otherwise specified on the data sheet, core and winding losses shall be optimized with the
transformer at 75 percent of loading at 75 qC. The standard reference temperature for the no-load losses
of transforms shall be 20 qC.
5.4.2 Losses shall be calculated in accordance with power cost data specified on the data sheet.
5.4.3 If the transformer total losses measured during the final test exceed the guaranteed losses by more
than that allowed by ANSI C57.12.00 - Table 16, the transformer manufacturer shall either rebuild the
transformer or rebate to SABIC a penalty per excess watt as specified on data sheet.
5.4.4 If the no-load losses exceed the guaranteed losses by more than that allowed by ANSI C57.12.00,
the transformer manufacturer shall either re-stack the core or pay a penalty per excess kilowatt for each
kilowatt over the guaranteed losses as specified on data sheets.
5.4.5 If the transformer losses are less than the guaranteed value, no incentive will be paid to the
manufacturer.
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5.4.6 The guaranteed core loss and load loss for each size of transformer shall be provided by the
manufacturer in his bid documents.
5.5 Bushings
5.5.1 Bushings located in air-filled terminal chambers shall be made wet process glazed with threaded
stud porcelain. Bushings for use above 15 kV shall be capacitor tap for testing power factor values.
5.5.2 Bushings mounted on the transformer cover or in oil filled terminal chambers shall be made of
porcelain.
5.5.3 Bushings shall have bolted construction. Gaskets shall be retained by positive means, for example
recessed spaces for gaskets, to avoid deformation when bushing is installed. Integrity of gaskets shall be
tested by pressurizing the tanks to a minimum of 0.87 kPa (6 psi) for 2 hours and checking for leaks.
5.5.4 Bushings shall have tin-plated copper pads with NEMA standard four-hole drillings (14.3 mm in
diameter: spaced 44.5 mm apart center to center) for the specified quantity and type of connections.
5.5.5 Neutral bushing shall be identical to phase bushings, that is, fully rated to minimize spare parts.
5.5.6 Neutral bushing shall be located in the terminal chamber or on the cover as indicated on the data
sheet.
5.5.7 The bushing with the same voltage rating shall not be interchangeable with the bushing that have
different design wtih much higher current value.
5.6 Tank and Enclosure
5.6.1 Transformer tank shall be designed to eliminate movement of the coils’ bushing terminals over the
full range of positive 1.45 kPa (10 psi) and negative 1.16 kPa (8 psi) pressures.
5.6.2 Assembled transformer shall be able to withstand, without permanent deformation, a pressure
25 percent greater than the maximum operating pressure. Certified design test data shall be provided to
SABIC if requested.
5.6.3 The inside of the tank shall be clean and free of slag and foreign particles after welding of the tank
cover.
5.6.4 Tank cover shall be continuously welded and shall have one manhole or two (2) hand holes. Manhole
is preferred, hand holes require approval from SABIC.
5.6.5 Manhole and hand holes shall have gasketed and bolted covers.
5.6.6 If manhole is round, it shall have a minimum diameter of 610 mm. If manhole is rectangular it shall
have a minimum dimension of 610 mm.
5.6.7 Manhole cover shall have a minimum of two handles for lifting.
5.6.8 A sealed tank construction shall be achieved by a formed flange, a flame and heat resistant gasket in
a retainer around the manhole and a main cover.
5.6.9 Hand holes shall be located and sized to permit change-out of bushings.
5.6.10 Transformer shall have two stainless steel grounding pads in accordance with ANSI C57.12.10,
Section 5.5.
5.6.11 Grounding pads shall be welded on the base or on the tank wall near the base and located to not
interfere with jacking facilities.
5.6.12 One grounding pad shall be located near the neutral bushing and the other shall be located on the
opposite side. Each pad shall be drilled and tapped for 13 mm thread at a minimum depth of 13 mm. Two
threaded holes spaced to suit a standard two-hole non-insulated compression lug shall be provided on
each pad. Plastic, flanged cup type thread protectors shall be inserted in each threaded hole prior to
shipping.
5.6.13 Lifting eyes or lugs shall be provided for lifting the cover, the core and coil assembly and the
complete transformer. The bearing surface of the lifting lugs shall be free of sharp edges and shall have a
minimum opening of 30 mm for guying purposes.
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5.6.14 Welded steel pads shall be located at the extreme or corners of the transformer tank to provide a
bearing surface for the jacks. The jack pads shall be accessible for the insertion of jacks when the
transformer is completely assembled, and the underside of the pads to the base of the transformer shall
be in line.
5.6.15 Tank bottom plate shall be raised from the normal foundation surface to prevent rusting of the tank.
Bottom plate shall be braced in a way that it does not sag. Tank bottom and the underside of supports shall
be coated with a rubberized asphalt compound.
5.6.16 Primary and secondary transformer interface shall permit removal of the transformer without
disturbing the adjacent switchgear. Disassembly of the transition section is acceptable.
5.6.17 A caution plate with black engraved letters on a yellow background shall be provided on each
manhole and hand hole cover and shall read:
CAUTION
PRESSURIZED ENCLOSURE
Do Not Open Unless Equipment Is De-energized
and Pressure has been Released
5.7 Cooling
5.7.1 Radiators shall be detachable panel type.
5.7.2 Panel type radiators shall be made of galvanized steel.
5.7.3 Unless specified otherwise on the data sheet, cooling fans shall be provided and sized to allow
continuous operation of the transformer at FA rating without exceeding the specified winding temperature
rise.
5.7.4 Fans shall be supported on brackets attached to the main tank and not to the radiators.
5.7.5 Fans shall be fitted with fan guards. Maximum size of opening on guards shall be 12.5 mm.
5.7.6 Operation of fans shall be controlled with a three-position selector maintained switch -
automatic/off/manual. In the automatic mode, fan operation shall be controlled as described below in 5.7.7
or 5.7.8 as applicable.
5.7.7 For transformers 2000 kVA and below, fan operation shall be controlled by the temperature of the
insulating liquid in accordance with Section 5.9.1.1 of ANSI C57.12.10.
5.7.8 For transformers above 2000 kVA, fan operation shall be controlled by the high temperature of the
winding in accordance with Section 5.9.1.2 of ANSI C57.12.10.
5.7.9 Provisions shall be made for remote maintained position contact to run the fans. Controller for the
fan shall have two (2) normally open auxiliary contacts wired to a terminal box to indicate fan operation.
5.7.10 Fan motors shall be 480 V, 3 phase, 60 Hz (ANSI/NEMA), totally-enclosed, squirrel cage, induction
type, rated for a 50 qC ambient. They shall conform to the requirements of NEMA MG1.
5.8 Terminal Chambers, External Clearances, and Space Heaters
5.8.1 Transformers shall have throat supported air terminal chambers (ATC) for high and low voltage
power termination for primary voltages up to 34.5 kV unless specified otherwise on the data sheet.
Transformer throat shall be drilled and gasketed. Gaskets shall be one piece cork neoprene material.
5.8.2 For primary voltages above 115 kV the terminal chamber shall be oil filled from the main tank. Fill,
drain and vent valves shall be provided. Valves shall be stainless steel with positive shut off. Piping and
piping fittings shall be hot dipped galvanized steel.
5.8.3 Terminal chambers shall have a front cover. Cover shall be gasketed with stainless steel hinges and
three points latching with pad locking provision.
5.8.4 Terminal chambers shall have a removable aluminum bottom plate, 6.35 mm thick minimum, to
accept multiple single conductor cables per phase. For single or multiple three conductor cables the plate
may be steel. Plate shall be bolted and gasketed.
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5.8.5 There shall be a minimum space of 838 mm between the cable entry point and the bottom of the
bushing connection pad.
5.8.6 Terminal chambers shall have the required cable supports spaced at a maximum distance of
305 mm.
5.8.7 When specified on the data sheet, connection shall consist of a drilled and gasketed flange on the
end wall of the tank, for close coupling of an off load primary disconnect switch.
5.8.8 Air filled terminal chambers shall have two drains at their lowest points. Drains shall have screens
made of 300 series stainless steel. Maximum size of screen opening shall be 3.17 mm.
5.8.9 Terminal chambers shall have a drip shield over all the horizontal gasketed surfaces.
5.8.10 External electrical clearances for exposed conducting parts shall be based on voltage and basic
impulse insulation level (BIL) levels specified. Certified testing proving adequate clearances shall be
performed on transformers prior to shipping.
5.8.11 Space heaters rated at 240 V single phase shall be provided inside each air filled terminal chamber.
5.8.12 Space heaters shall:
a. Be operated at 120 V ac
b. Have an expanded metal mesh cover to prevent accidental contact with hot surfaces
c. Be controlled by an adjustable thermostat with a bypass switch for manual operation
d. Be individually fused and wired to a separate terminal strip in control cabinet specified in 5.11
e. Be mounted on suitable standoff insulators to prevent hot spots on the outside of the terminal
chambers
f. Have an ammeter to continually monitor space heater operation
5.8.13 Terminal chambers containing space heaters shall have a sign on the cover, with a yellow
background and black engraved lettering, that reads as follows in both Arabic and English. SABIC will
furnish Arabic translation to the manufacturer.
CAUTION
Space Heaters May Be Energized
5.8.14 The high voltage terminal chamber shall include grounding terminals for the grounding of cable
armor, shield and stress relieving devices.
5.9 Accessories
5.9.1 General
5.9.1.1 Monitoring and measuring instruments shall be mounted at grade level. View of the instruments
shall not be obstructed when viewing from the grade level. Oil sampling valve shall not be located under or
above the radiators.
5.9.1.2 Transformers shall have a dial type temperature indicator to indicate temperature of the insulating
liquid. The indicator shall have two hermetically sealed normally closed contacts that are adjustable from
55 qC to 120 qC. The indicator shall be provided with a floating pointer to show the maximum indication
since the last setting and shall be capable of being reset without the use of tools. Resetting by means of a
permanent magnet permanently attached to the indicator by a chain or otherwise will be acceptable.
5.9.1.3 Transformers shall have the following accessories:
a. Standard ANSI accessories as listed in ANSI C57.12.10 Table 11 under Power BIL column
b. Gas sampling valve
c. Automatic resetting tank pressure relief device with indication of operation, and hermetically
sealed normally closed alarm contact
d. Upper filter valves
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e. Nitrogen purge nozzle and shut-off valve

f. Drain and filter valve (oil sampling valve). This valve shall not be located under or above the
radiators.
5.9.1.4 Transformers above 2000 kVA shall have a dial type winding temperature indicator located at a
maximum of 1.7 m above the transformer base on the high voltage side. It shall be provided with two
single pole double throw hermetically sealed contacts adjustable from 65 qC to 125 qC, and a floating
pointer to show the maximum temperature indication since the last setting. The floating pointer shall be
capable of being reset without tools. Resetting by means of a permanent magnet permanently attached to
the indicator by a chain or otherwise will be acceptable. The indicator shall include the necessary current
transformers and heaters to indicate the hottest spot of the windings under all specified loading conditions.
5.9.1.5 Transformers shall have a magnetic type level indicator for the insulating liquid. Indicator shall
have a 138 mm dial and nonadjustable alarm contacts set to close at the minimum safe operating level of
the insulating liquid. Indicator shall also have permanent markings that indicate the insulating liquid level at
25 qC. The indicator shall be readable from the transformer base level.
5.9.1.6 Contacts shall be wired with color coded conductors and have permanent labeling (wire markers)
at the control box end in conformance with ANSI C57.12.10, Section 9.7.2.
5.9.1.7 Transformer shall have a stainless steel nameplate mounted on the tank at approximately
eye-level. This shall include the following information, and also manufacturer standard items not covered
herein:
a. Serial number
b. Class (OA, OF/FA, etc.)
c. Number of phases
d. Frequency
e. kVA (or MVA) rating
f. Voltage ratings
g. Tap voltages
h. Temperature rise, qC
i. Polarity
j. Phasor diagram (polyphase transformers)
k. Percent impedance
l. Basic lightning impulse insulation levels (BIL)
m. Approximate masses in kg
n. Connection diagram
o. Name of manufacturer
p. Installation and operating instructions reference
q. The word transformer or autotransformer
r. Step-up operation suitability
s. Tank, pressure, and liquid data
t. Type of insulating liquid (generic name preferred)
u. Conductor material (of each winding)
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5.9.2 Current Transformers

5.9.2.1 High voltage winding current transformers (CT’s) shall be multi-ratio with taps as specified in
ANSI C57.13.
5.9.2.2 CT’s located in air-filled terminal chambers shall be constructed of oil resistant insulating materials.
5.9.2.3 Accuracy class (full winding) shall conform to Table 6 in ANSI C57.13.
5.9.2.4 Secondary leads shall be run to shorting type terminal blocks located in a control junction box on
the side of the transformer tank. Terminal blocks shall be clearly marked designating the CT phase and tap
number in accordance with ANSI C57.13.
5.9.2.5 Insulated, brazed-seam ring-type lugs shall be used for CT circuits.
5.9.2.6 The secondary lead wire shall be 10 AWG, wire routed in rigid metal conduit from the junction box
on the transformer.
5.9.3 Current Monitoring System for Cooling Fans
5.9.3.1 System shall have minimum two (2) normally open (NO) and two (2) normally closed (NC) alarm
contacts for customer use, to indicate nonfunctional fans with fan control switch in the manual mode, or in
the automatic mode when the fan operation is required as described in 5.6.
5.9.3.2 Manufacturer shall provide a complete description of the system with the quotation.
5.9.4 Sudden Pressure Relay
5.9.4.1 Unless specified on the data sheet, transformers 1000 kVA and above shall have a sudden
pressure relay with alarm and shutdown contact. The relay circuit and its contacts shall operate at 125 V dc
from the station battery.
5.10 Hardware
5.10.1 Hardware not under oil, for example bolts, screws, fasteners, and plugs, shall be made of 300
series stainless steel.
5.10.2 Bolts shall have captive hexagon heads.
5.10.3 Bolt connections to the transformer enclosure shall be made using threaded openings on the
enclosure or nuts welded inside the enclosure.
5.10.4 Hexagonal nuts shall be used for welded studs.
5.11 Alarm and Control Devices
5.11.1 Alarm and control devices shall have single-pole, double-throw contacts. Contacts shall be rated in
accordance with ANSI C57.12.10, Section 9.7.1.
5.11.2 Alarm and control devices shall:
a. Be clearly identified on the drawings
b. Have identification plates nearby. Plates shall be mounted with stainless steel screws or drive
pins
5.11.3 Identification plates shall be made of laminated material and shall be white with black engraved
lettering.
5.12 Wiring and Control Cabinet
5.12.1 Control, alarm, and power wiring shall:
a. Contain no splices
b. Be run in rigid galvanized steel conduit and short lengths of liquid-tight flexible conduit
c. Be minimum 2.5 mm2 stranded copper for control and alarm circuits
d. Be minimum 4 mm2 stranded copper for power circuits
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e. Wiring shall be 90q XHHW as defined by NEC Table 310-13

5.12.2 Wires shall be identified at both ends with permanent wire markers. Stick-on wire markers and wire
supports are not acceptable.
5.12.3 Wiring, except CT wiring, shall be terminated with locking-fork, insulated, brazed-seam type
connectors (see 5.9.2.5 for CT wiring).
5.12.4 Wiring shall be terminated in terminal strips in the control cabinet. Terminal blocks shall be of solid
one-piece design with an inter-phase barrier and hinged plastic covers.
5.12.5 Auxiliary contacts shall be wired to terminals in the control cabinet.
5.12.6 Control cabinet shall:
a. Be NEMA 4X
b. Be made of 300 series stainless steel
c. Have a continuously hinged door that can be padlocked
d. Not be mounted on radiators or on the high or low voltage terminal chambers
5.12.7 Wiring entrances to the control cabinet shall be made through the sides or bottom.
5.12.8 Control cabinet shall have a drain with stainless steel screen at its lowest point.
5.12.9 Control cabinet shall have separate terminals for SABIC’s power and control wiring. These
terminals shall be identified as such. Terminal blocks shall be one-piece, phenolic barrier type, rated at
20A, 600 V minimum with pre-numbered marking strips, suitable for two terminations per point. A
maximum of two wires per point is permitted.
5.12.10 Control cabinet shall not have any sharp edges or corners inside or outside.
5.12.11 Disconnect devices shall be identified with engraved nameplates and shall have provisions for
padlocking in the ‘off’ position. Relays, switches, terminal blocks and other devices shall be identified by
engraved nameplates. Nameplates on exposed surfaces shall be securely attached without the use of
adhesives. Adhesives may be used on nameplates attached to internal surfaces of control panels and
similar enclosures.
5.12.12 Terminals for wiring 50 V and higher shall be guarded.
5.12.13 All energy isolating devices shall be lockable in the OFF or disconnect position.
5.12.14 Control cabinets shall be provided with a 240 V rated space heater with thermostat to be operated
at 120 V, a 120 V convenience outlet and a switched 120 V overhead light. A door-mounted ammeter shall
be provided for indication of space heater operation. A wiring diagram indicating the control cabinet
circuits and fuse or circuit breaker operation shall be affixed inside the cabinet door.
5.13 Audible Sound Levels
When tested in accordance with ANSI C57.12.90, audible sound levels produced by the transformer shall
not exceed the values given below:

OA kVA Rating W/O Fans (dBA) With Fans (dBA)

Below 1000 58 67
1001-2000 61 67
2001-3000 63 67
3001-5000 65 67
5001-7500 67 69
Above 7500 68 70
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5.14 Coatings
5.14.1 General
5.14.1.1 Transformer assembly (including tank, radiators, throats and terminal chambers) containing
external ferrous parts shall be cleaned to near white metal and sealed with a moisture resistant, long-life
coating.
5.14.1.2 Finish coat shall have a nonmetallic pigment surface. Color of finish coat shall be light gray
number 61 in accordance with ASTM D 1535. (Munsell Notation 8.3 G6 10/0.54) and covered with an
epoxy coat for protection against chalking and fading due to environmental conditions.
5.14.1.3 A litre of touch up paint with a Material Safety Data Sheet (MSDS) sheet for the finish coat shall
be provided.
5.14.1.4 Base of the tank and channels shall be coated with an asphalt-based paint.
5.14.2 Coating System Qualification
5.14.2.1 Coating system shall be qualified by testing a minimum of four panels.
5.14.2.2 Panels shall be of standard thickness ferrous metal equivalent to that used for the transformer
enclosure.
5.14.2.3 Test panels shall be coated with the same coating to be used on the transformer enclosure and
shall be allowed to age for a minimum of seven days before being tested.
5.14.2.4 Test apparatus shall conform to ASTM B 117.
5.14.2.5 Two of the test panels shall be scribed.
5.14.2.6 Panels shall be tested in accordance with ASTM D 1654. Panels shall be tested in a salt spray
chamber for a continuous period of 200 hours except for the interruptions required to inspect the panels or
replenish the solution in the reservoir.
5.14.2.7 After completion of the time period in the salt spray chamber, the test panels shall be processed in
accordance with ASTM D 1654.
5.14.2.8 Evaluation of the coating performance shall be conducted on the scribed panels and shall be
judged to be acceptable if their rating number is 5 or higher as determined by ASTM D 1654.
5.14.2.9 Coating on unscribed panels shall be judged to be acceptable if their blistering size is 6 or higher,
and their frequency designation is F or M, as determined by ASTM D 714.
5.14.2.10 Vendor shall provide data for qualification of the proposed coating system.
5.15 Manual Tap Changer
5.15.1 High voltage winding shall have a manual tap changer, in accordance with Section 5.1.1 of
ANSI C57.12.10, for de-energized operation. The tap changer shall be capable of all voltage requirements
and handling the maximum 65 qC current in the winding.
5.15.2 Tap changer handle shall be able to be padlocked, and shall have visible indication of the tap
position without unlocking.
5.15.3 The mechanism shall be of a type that it will be impossible to leave a winding open or short circuited
when the operating handle is placed in a locked position.
5.15.4 For a given winding, the number ‘1’ or the letter ‘A’ shall be assigned to the tap that has the greatest
number of effective turns.
5.15.5 Unless otherwise specified on the data sheet, tap changer shall:
a. Be four-position
b. Have four (4) 21/2 percent full capacity taps, two above and two below rated primary voltage
c. Be located on the side of the transformer tank
5.15.6 There shall be a minimum of 1 square inch mating surface between tap changer contacts.
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5.15.7 A caution plate (black engraving on yellow background) shall be provided adjacent to tap changer
indicating in both Arabic and English:
‘Do not operate when transformer is energized’
5.16 On Load Tap Changer
5.16.1 Transformers with primary voltage of 115 kV and above shall be provided with an automatic On
Load Tap Changer (OLTC).
5.16.2 The preferred method of tap changing is that using the high-speed transition, resistor principle, but
methods using a reactor or autotransformer are acceptable if there is an economic advantage to SABIC.
See Figure 1 for the circuit and description of operation of the preferred method.
5.16.3 The resistor principle of on line tap changing has the advantage of relatively small sized resistors
being required, but requires a transformer tap for each voltage required. The reactor or auto transformer
principle uses a tap bridging position for operating voltage, thus requiring half the number of transformer
taps. This method can also be used for resistors to increase the life of diverter switches.
5.16.4 The number of taps and voltage tap range shall be as specified in the engineered equipment
specification, but shall not be less than 16 and r10 percent respectively.
5.16.5 The arrangement of selector switch and diverter switch shall be the manufacturer’s standard, but
the minimum requirement is that the diverter switch shall be mounted in a separate oil tank mounted inside
the transformer main tank. The diverter switch oil tank shall be accessible from the top cover of the
transformer main tank enabling the switch to be removed from its tank for maintenance if required. It shall
be fitted with a pressure relief diaphragm with single pole, double throw alarm contacts, local position
switch indicator and provision for analog or digital remote indication of the actual OLTC position. Operation
of the tap changer shall be by single or three phase totally enclosed induction motor. Manual emergency
crank, motor protection devices and mechanical and electrical overrun protection shall be provided.
5.16.6 Voltage control shall be fully automatic by means of a solid state voltage controller mounted locally
or, if provided, at the transformer supervisory panel.
5.16.7 Transformers with three windings shall be provided with an on-load tap changer on the secondary
windings and on the tertiary winding. Each on load tap changer shall operate independently.
5.17 Short Circuit
5.17.1 The transformer shall be capable of withstanding without damage, the mechanical and thermal
stresses caused by short circuits on the external terminals of any winding or windings in accordance with
ANSI C57.12.90. In determining the maximum short circuit current, only the impedance of the transformer
shall be considered.
5.17.2 The manufacturer shall furnish proof of successful short circuit testing with the quotation.
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5.18 Basic Impulse Insulation Level (BIL)

Transformer Winding and Bushing Insulation Levels shall not be less than the following:

Table I
Distribution Levels for Transformers Below 2500 kVA

WINDINGS BUSHINGS

Insulation Class BIL Insulation Class BIL

kV kV kV kV

1.2 30 1.2 45

5.0 60 5.0 75

15.0 95 15.0 95

Table II
Power Levels

Rated WINDINGS BUSHINGS(1)

Voltage - kV
of Windings Insulation BIL Insulation BIL
(Line to Line) Class - kV kV Class - kV kV

0.48 1.2 45 5.0 60

4.16 5.0 75 5.0 96

13.8 15.0 110 15.0 125

34.5 34.5 200 34.5 200

115.0 115.0 550 115.0 650
230 230.0 900 230.0 1050

(1) Values apply to phase and neutral as well as lightning arrestor bushing.

5.19 Lightning Arresters

When transformers are directly connected to exposed systems, GIS type lightning arresters shall be
furnished. They shall be mounted near the primary side phase bushings and supported from the
transformer tank and shall include a surge counter for maintenance purpose.
5.20 Harmonics
If transformers are to be used to supply nonlinear loads, the necessary information shall be specified on
the data sheet.

6. Captive Transformers
6.1 When a transformer is to be used as a captive transformer and the load is a motor, motor rating, type
of starting, magnitude of starting current and frequency of starting shall be specified on the data sheet.
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Transformer shall be designed and constructed to withstand the mechanical and thermal stresses of the
duty specified.
6.1.1 The curves in Figure 2 show the voltage drop across a typical transformer when starting
synchronous or squirrel-cage induction motors connected to the transformer secondary.
6.1.2 Figure 2 plots secondary voltage on motor starting, expressed in percent of initial secondary voltage
against motor starting kVA, expressed in transformer - bank kVA. The percent transformer-bank kVA is the
kVA which would be drawn by a motor if rated transformer secondary voltage is maintained.
6.1.3 Motor starting power factors for the curves in Figure 2 are in the 10 to 40 percent range.

7. Insulation System
7.1 Turn Insulation
Turn insulation shall be electrically and mechanically suitable for operating voltages, surge voltages and
environmental conditions involved in the manufacture, normal installation or shipment of the transformer.
Insulation shall be of a proven record, or adequate performance data shall be submitted for SABIC
approval.
7.2 Insulation Life
Insulating materials shall be suitable for continuous operation at rated load for the normal life of the
transformer.
7.3 Liquid Insulating System
7.3.1 Transformer tank shall be filled with a suitable insulating liquid in accordance with the data sheet.
7.3.2 Unless specified otherwise, insulating liquid shall be new, unused, Type II mineral oil that conforms
to ASTM D3487.
7.3.3 Insulating liquid shall be low flammability fluid if specified on the data sheet.
7.3.4 Transformer and its accessories shall be designed to accommodate the unique properties of each
insulating liquid with regards to compatibility with other material used in the transformer, heat transfer
capability and thermal expansion coefficient.
7.4 Liquid Preservation System
Space above the insulating liquid shall be filled with clean, dry nitrogen to a minimum pressure of
0.435 kPa (3 psi).

8. Tests
8.1 Standard Tests
8.1.1 All routine tests listed in ANSI C57.12.00 Table 19 shall be performed on transformers prior to
shipment and certified test results provided to SABIC.
8.1.2 Certified data for calibration and maintenance requirement of the pressure relief device shall be
provided to SABIC.
8.1.3 Tests shall be performed in accordance with ANSI C57.12.90.
8.1.4 Mineral-oil-immersed transformers shall be tested for concentration of individual gas and total
dissolved combustible gas (TDCG) in oil, and total combustible gases (TCG) in the space above the oil.
The transformer shall be acceptable if the levels of the gases do not exceed the levels established in
Condition 1 in Tables 1 and 2 of ANSI C57.104. TCG level shall be measured for a 24 hour period to
confirm a TCG rate of less than 0.01 percent per day.
8.1.5 A partial discharge (PD) and Radio Influence Voltage (RIV) test shall be performed for transformers
with windings operating at 13.8 kV and higher. These tests shall be performed at 150 percent of line to
ground voltage. PD and RIV levels shall not exceed 500 pC and 100 PV respectively.
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8.1.6 Copies of complete certified test reports shall be sent to SABIC prior to shipment of the transformer.
8.1.7 Impact on cost and delivery of each optional test required on the data sheet shall be indicated with
the quotation. A list and description of tests shall be shown on the data sheet.
8.1.8 Transformers that do not pass the specified test shall not be shipped without written approval from
SABIC.
8.2 High Potential Test
8.2.1 A dc high potential test may be performed by SABIC at site prior to energizing the transformer. Site
test shall be conducted at the same value as dc high potential test performed in the factory by the
manufacturer.
8.2.2 Manufacturer shall indicate maximum dc high potential test value in the instruction book and on the
transformer nameplate.
8.3 Miscellaneous Tests on Insulating Liquid
8.3.1 Mineral oil insulating liquid shall be tested for contamination by silicone or other incompatible fluids.
8.3.2 Silicone insulating liquid, or other low flammability liquids, shall be tested for contamination by
mineral oil or other incompatible fluids.
8.4 Certification
8.4.1 The vendor shall provide written certification that materials used in the manufacture of the
transformer are asbestos-free.
8.4.2 Liquids shall be certified to contain less than 1 ppm PCBs.

9. Lifting, Moving, and Jacking Facilities

Lifting, moving, and jacking facilities shall conform to ANSI C57.12.10, Section 5.3.

10. Documentation
10.1 Documentation shall meet the following requirements:
a. Assembly drawings showing plans, front and side view elevations and typical sectional views
shall show locations of all equipment and devices
b. Transformer installation drawings showing dimensions, weights, location, and type of all
connections
c. Bill of materials giving schematic identification, quantity, make, rating, model, and manufacturer
of components
d. Drawings shall be provided on CAD compatible electronic format in addition to hard copies of the
drawings requested in the data sheet
e. Proper assembly and testing instructions shall be provided in the installation manual
f. Certified reports of tests shall be provided to SABIC
g. Installation and maintenance manuals with complete maintenance requirements, procedures and
frequency, for each component requiring periodic maintenance. This shall include testing method and
frequency for testing the integrity of pressure relief devices.
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10.2 Vendor Drawing and Data Requirements

A B C D DESCRIPTION

X X X Detailed bill of material

General layout of equipment, showing dimensions,

X X X X weights, locations, and outline drawings showing the
final assembled configuration.
X X X Connection wiring diagrams for all electrical equipment.
X X X Single-line, 3-line, and control schematic diagrams
X Data for qualification of coatings
X Certified test reports

X(1) Installation, operation and maintenance manual

X Final as-built drawings
X X Recommended-price spare parts list:

Key:
A. Bidder shall furnish these documents with proposal.
B. Vendor shall furnish these documents for SABIC review and
authorization to proceed before fabrication.
C. Vendor shall furnish these documents as part of the final certified
document submittal.
(1) Equipment should be shipped with one set of installation,
operation, and maintenance manuals.
D. As-built within 2 weeks following shipment.

11. Shipping
11.1 Transformers shipped with insulating liquid in the tank shall have the tank filled with a nitrogen
blanket at a pressure of 0.435 kPa (3 psi). Pressure and temperature of insulating liquid and nitrogen
blanket shall be recorded on a tag attached to pressure-vacuum gage.
11.2 Transformers for which the oil is shipped separately shall be shipped filled with dry nitrogen under
pressure with a pressure gage attached, and with a container of dehydrating material mounted temporarily
inside the transformer tank. If the transformers are to be in transit for more than 14 days, a cylinder of dry
nitrogen shall be connected temporarily to each transformer tank through suitable valves for maintaining
pressure while the transformers are in transit.
11.3 Transformer components, for example cooling radiators and bushings, that have to be shipped
separately from the transformer shall be prepared in a manner that excludes moisture and prevents
damage.
11.4 Bushings mounted on the cover shall be protected during shipping.
11.5 Bushing pads shall be cleaned of foreign coating materials prior to shipping.
11.6 A minimum of two (2) free access, impact recorders shall be mounted on each transformer during
shipping.
11.7 Details of shipping requirements will be furnished in the purchase order. If required, the vendor shall
ship the equipment with an impact meter. The meter shall be a ‘Go/No Go’ type truck shipment.
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11.8 Temporary shipping braces shall be painted yellow and marked:

‘To be removed before equipment is placed in service’

12. Erection Assistance

12.1 The transformer manufacturer shall furnish technical assistance during erection, adjustment and
energization of transformers at the request of SABIC.

FIGURE 1
Description of Operation
High-Speed Transition, Resistor Principle of On Load Tap Changer

1. Figure 1 shows tap selectors 1 and 2 connected to alternate taps in the transformer winding and tap 1
connected through contactor or diverter switch C.
2. To switch to tap 2, contactor/diverter switch C is progressed through the contacts from 1 and R1, to R1
only, to R1 and R2, to R2 only and finally to R2 and 2.
3. To switch to tap 3, selector 1 is moved to an alternate tap connection and the contactor/diverter switch
C is progressed back through the contacts in the reverse order from R2 and 2 to 1 and R1. The resistors
bridge the taps during switchover, but are designed to carry current for a very short duration. For this
reason the contactor/diverter switch C moves through the contact sequence in very few cycles of current.
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FIGURE 2
Voltage Drop Through a Typical Transformer
(When Starting Induction Motors Connected to the Transformer Secondary)