General Requirements - Replacement of XQT-1.pdf

XQT-1 “Big Blue” Sources Sought

TITLE

XQT-1 “Big Blue” Transformer Replacement for PPPL: Request for Industry Input

DESCRIPTION

Princeton Plasma Physics Laboratory (PPPL) has developed a long-term initiative to make mission critical improvements to its offices and lab facilities. These improvements are needed to support PPPL’s unique competencies and close capability gaps to support laboratory programs. Part of this initiative includes the modernization of PPPL’s aging electrical infrastructure.

PPPL intends to replace the existing XQT-1 “Big Blue” transformer located in it’s 138kV switchyard. This transformer was originally installed in 1958 and has far exceeded its expected useful life of 30 years, showing significant signs of wear and deterioration. XQT-1 steps down the incoming utility voltage for C-

Site campus distribution. It has dual secondary windings to serve both “house” and “experimental” loads.

This configuration is not ideal and is one of the reasons why PPPL intends to replace XQT-1 with (2) new transformers, XQT-1 and XQT-4, to allow for the separation of the different load types.

Given the criticality of this project, PPPL is issuing this Pre-Solicitation to request input on cost, lead time, and industry trends to refine the replacement transformer specifications and scope of work in advance of issuing the RFP. The intent of this approach is to accommodate flexibility in meeting project requirements to ultimately lead to a successful procurement process.

PRELIMINARY SCOPE

The existing XQT-1 is rated at 30MVA with a 138kV primary winding and a dual 4.16kV secondary winding.

This transformer will be replaced by two new transformers designated as XQT-1 and XQT-4. The new XQT-

1 transformer will be base scope and the new XQT-4 transformer will be an add-alternate. The scope of work for each new transformer is as follows:

• XQT-1 Transformer (Base Scope):

o Furnish (1) 10MVA transformer with a 138kV primary winding and 4.16kV secondary winding. Delivery of the transformer to the project site shall include permitting, utility modification, tree trimming, and roadway escorts as needed.

o Provide warranty coverage and site support during installation and commissioning of the transformer. Warranty coverage shall be (12) months after first energization or (24) months after leaving the Subcontractor’s factory, whichever comes first.

o Provide factory and site acceptance testing. Site acceptance testing shall include a temperature rise test and short circuit withstand test.

o Provide transformer accessories, including current transformers (CTs), dry contacts for monitoring, and lightning arrester

• XQT-4 Transformer (Add-Alternate):

o Furnish (1) 30MVA transformer with a 138kV primary winding and 4.19kV secondary winding. Delivery of the transformer to the project site shall include permitting, utility modification, tree trimming, and roadway escorts as needed.

o Provide warranty coverage and site support during installation and commissioning of the transformer. Warranty coverage shall be (12) months after first energization or (24) months after leaving the Subcontractor’s factory, whichever comes first.

o Provide factory and site acceptance testing. Site acceptance testing shall include a temperature rise test and short circuit withstand test.

o Provide transformer accessories, including current transformers (CTs), dry contacts for monitoring, and lightning arrester.

o Furnish (1) new 138kV primary disconnect switch.

The following table includes the preferred technical characteristics of the (2) new transformers. Please either confirm that you will comply with these requirements or propose alternatives. For oil type, please verify whether the transformer being proposed will utilize mineral oil or FR3.

Description Owner

Requirement 1st

Transformer

Owner

Requirement 2nd

Transformer

Will Comply /

Proposed Alternative

Equipment Identifier XQT-1 XQT-4

Applicable Standard IEC 60076 IEC 60076

Type 3-phase 3-phase

Installation Outdoor Outdoor

Cooling Method ONAN/ONAF/ONAF ONAN/ONAF/ONAF

Oil Type Mineral or FR3 Mineral or FR3

Frequency, Hz 60 60

Rated Voltages: Primary Side

(kV)

144.9/141.45

134.55/131.1

144.9/141.45

134.55/131.1

BIL: Primary Side

(kV)

650 650

Rated Voltages: Secondary Side

(kV)

4.16 4.16

BIL: Secondary Side

(kV)

75 75

Rated Power (at 50°C rise):

ONAN/ONAF/ONAF, MVA

10,14,18 30,40,50

Overload capacity Per IEC 60076-7 Per IEC 60076-7

Rated Power (at 60°C rise):

ONAN/ONAF/ONAF, MVA

11.2,15.7,20.2 33.6,44.8,56

Neutral of secondary winding To be earthed through an impedance

To be earthed through an impedance

Impedance tolerances Per IEC 60076-1 Per IEC 60076-1

Maximum core over-excitation, continuous duty, full load, %

105 105

Maximum Noise Level: NEMA TR1 dB(A) at

105% rated voltage and maximum MVA load

NEMA TR1 dB(A) at

105% rated voltage and maximum

MVA load

Lightning Arresters: Primary

W/ counter. (kV)

121 121

Lightning Arresters: Secondary

W/ counter. (kV)

5 5

Primary terminal phase connections

Suitable for connection to overhead conductors, stranded Almelec aluminum alloy type ASTER 570

Suitable for connection to overhead conductors, stranded Almelec aluminum alloy type ASTER 570

Secondary terminal phase connections

Bus Bar Bus Bar

Bushing Primary CT’s (X2) Multi Ratio Multi Ratio

Bushing Secondary CT’s (x2) Multi Ratio Multi Ratio

Ground Resistor CT (X1) Fixed Fixed

Liquid Level Gage Yes Yes

Liquid Temp. Gage- Direct Yes Yes

Liquid Temp. Gage- Eye Level Yes Yes

Winding Temp Gage - Direct Yes Yes

Winding Temp Gage - Eye Level Yes Yes

Pressure Relief Device Yes Yes

Sudden Pressure Relay Yes Yes

Rapid Pressure Rise Relay Yes Yes

Deenergized Tap Changer Yes Yes

Positive Pressure Oil Preservation

(Dry Nitrogen)

Yes Yes

Neutral Ground Resistor Yes Yes

Removable Radiators W/ Valves Yes Yes

WP Control Cabinet W/ light &

120V rec.

Yes Yes

Additional Features See Note 3

Testing IEEE C57.12.00 IEEE C57.12.00

Notes:

1. All relay contacts to be rated 125V DC.

2. All alarm contacts to be wired to Control Cabinet.

3. Loads served by this transformer will include pulsed rectified power supplies. These loads can be pulsed on and off at a rapid rate. The transformer shall be designed to withstand the stress and fatigue for the following conditions:

a. Operation with R.M.S. KVA not exceeding the rated value when integrated over any period of time over a 5 min period.

b. 10,000 pulses at 120 MVA with a 5 sec. pulse duration at a rate not to exceed 30 sec.

c. 100,000 pulses at 90 MVA with a 5 sec. pulse duration at a rate not to exceed 30 sec.

d. 1,000,000 pulses at 60 MVA with a 5 sec. pulse duration at a rate not to exceed 15 sec.

PRELIMINARY PROCUREMENT TIMELINE

Please refer to the below anticipated project timeline.

Issue RFP September 4, 2024

Proposals Due September 25, 2024

Source Selection October 9, 2024

Award Contract October 31, 2024

BASIS OF DESIGN REPORT smithgroup.com 11 Project Number 14857.000

Medium-Voltage Transformer Replacements and Additions

ED-01 - Replacement of XQT-1 Transformer in C-Site 138 kV Yard

Recommendation: Threshold

Overview

Transformer XQT-1 is located in the ‘138kV Utility Yard’. The transformer steps down 138kV utility voltage to the C-Site campus distribution voltage of 4.16kV. The transformer is rated at 30MVA with a 138kV primary winding and dual 4.16kV secondary windings. 30MVA Transformer XQT-1 will be replaced by two transformers designated as XQT-1 and XQT-4. New transformer XQT-1 will be rated for 10MVA and XQT-4 will be rated 30MVA.

Operations Impact – One of Transformer XQT-1 secondary windings provides redundant power, via Transformer XQT-2 to switchgears Q1 and Q6; the other secondary winding provides redundant power, via Transformer XVT-1 to switchgears Q3 and Q4.

• If XQT-1 fails and XQT-2 fails then Switchgear Q1 and Q6 are left without power.

o Switchgear Q1 feeds C50 BLDG.

o Switchgear Q6 feeds the ICRF #1 & #2 LHCD, ICRF/FMIT #3, 4, 5, 6.

• If XQT-1 fails and XVT-1 fails then Switchgear Q3 and Q4 are left without power.

o Switchgear Q3 feeds Substations 9A, 9B, 10, 11, 12, Switchboard SWBD-P1 (LSB-West), and Switchboard SWBD-P2 (LSB-East).

o Switchgear Q4 feeds Substations 1, 2, 4, 5, 6, 13, 14, 15, 17, MCC-Q3-8A, MCC-Q3-9, and

Substation QPT-3.

This project is to be separately funded, however the CIRR project will include the full design of both transformers. See cost estimate in Appendix E for project cost separately tracked.

Scope of Work

• Disconnect and remove existing XQT-1 transformer and associated primary service conductors back to existing primary 1200A, 138kV switch XD-2.

• Provide (2) new liquid-filled (mineral oil) transformers to replace existing XQT-1. These transformers shall be identified as XQT-1 and XQT-4 and installed as described below:

o XQT-1: 10MVA, liquid-filled (Mineral oil), 138kV primary – 4.16kV secondary.

▪ Transformer primary feeder: 397.5kcmil Bare Aluminum Conductor, Steel

Reinforced (ACSR), 26/7 strand, code “IBIS”, 0.783” diameter. The feeder will originate from existing switch XD-2-upstream of existing switch XD-10 served from the 138kV aerial service line.

▪ The secondary of new transformer XQT-1 shall serve existing 4.16kV switchgear Q3 located in existing MG Building (C51).

▪ Provide new dedicated 500kcmil (5KV shielded MV-105 133% rated) conductors in existing overhead outdoor cable tray from XQT-1 secondary to existing Q3 Switchgear.

o XQT-4 shall be a 30MVA, liquid-filled, 138kV primary – 4.16kV secondary.

▪ Transformer primary feeder: 397.5kcmil Bare Aluminum Conductor, Steel

Reinforced (ACSR), 26/7 strand, code “IBIS”, 0.783” diameter. The feeder will originate from a new high-voltage disconnect switch. The new switch will match the existing site standard units. The primary side of the switch will connect to the existing PSE&G service feeder.

▪ The secondary of new transformer XQT-4 shall serve new 4.16kV Q2 switchgear.

New switchgear Q2 will be located in existing MG Building (C51).

FOR CONTEXT ONLY. REFER

TO SCOPE OF WORK IN

XQT-1 "BIG BLUE" SOURCES

SOUGHT DOCUMENT.

BASIS OF DESIGN REPORT smithgroup.com 12 Project Number 14857.000

▪ Provide new dedicated 500KCMIL (5KV shielded MV-105 133% rated) conductors in existing overhead outdoor cable tray from new XQT-4 secondary to new switchgear Q2.

• As an alternative to the 5kV conductors described above, the use of copper tubing conductors will be analyzed as the design progresses.

• Provide new galvanized structural steel dunnage for support of each new transformer.

Provide allowance of 1.5 tons of structural steel at each transformer location.

• The new XQT-1 and XQT-4 dunnage platforms will be supported by new (6) – 30-inch diameter by 4-foot deep reinforced concrete sonotube pier foundations.

o The existing transformer foundation for XQT-1 will be evaluated for reuse as the design progresses.

Priority

Overall Priority: 2.75

• System Age/ Reliability/Condition:

The transformer was originally installed in 1958. Although routine maintenance is performed on the transformer, the unit has far exceeded its expected useful life of 30 years and is showing significant signs of wear and deterioration.

• Sustainability/ Energy Savings: 2 The existing transformer does not meet the newest DOE transformer efficiency requirements.

• Mission & Critical – Closing Capability Gaps: 3 The age and condition of the transformer poses risks to power reliability to the loads served.

• Mission & Critical – Lab Plan Alignment: 2 The transformer serves labs. The age and condition of the transformer poses risks to power reliability to the loads served.

• Health and Safety: 3 The transformer is nearing its useful life and may present safery hazards and maintenance challenges.

ED-02 – Replacement of XQT-2 Transformer in C-Site 138 kV Yard

Recommendation: Threshold

Overview

Transformer XQT-2 is located in the ‘138kV Utility Yard’. The transformer steps down 138kV utility voltage to the C-Site campus distribution voltage of 4.16kV. The transformer is rated at 30MVA with a 138kV primary winding and a 4.16kV secondary winding. Transformer XQT-2 (30MVA) will be replaced in place by a new 30MVA transformer labeled XQT-2.

The unit was originally installed in the 1970s. According to PPPL engineering, this unit has undergone at least two major repairs to keep it in operation. Although routine maintenance is performed on the transformer, the unit has far exceeded its expected useful life of 30 years and is showing significant signs of wear and deterioration.

Operations Impact – Transformer XQT-2 serves Switchgear Q6. Switchgear Q6 receives redundant power from transformer XQT-1, which is also in poor condition. If XQT-2 and XQT-1 fail then Switchgear Q1 and Q6 are left without power. Q6 feeds the ICRF #1 & #2 LHCD, ICRF/FMIT #3, 4, 5, 6. Q1 feed C50 BLDG.

pegan Image pegan Cloud pegan Callout Existing XQT-1 to be replaced pegan Cloud pegan Callout Proposed Location for XQT-4 pegan Cloud pegan Callout Existing sump (no oil minder system)