Materials System Specification

55-SAMSS-003 26 April 2011

ESP Transformers - Outdoors
Document Responsibility: Electric Submersible Pump Standards Committee

Saudi Aramco DeskTop Standards

Table of Contents

1 Scope............................................................. 2
2 Conflicts and Deviations................................ 2
3 References..................................................... 2
4 Definitions...................................................... 3
5 General.......................................................... 3
6 Service Conditions......................................... 4
7 Rating............................................................. 5
8 Construction................................................... 6
9 Testing......................................................... 13
10 Shipping....................................................... 13

Previous Issue: New Next Planned Update: 26 April 2016

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Primary contact: Somali, Abdullah A. on 966-3-8731028

Copyright©Saudi Aramco 2011. All rights reserved.

Document Responsibility: Electric Submersible Pump Standards Committee 55-SAMSS-003
Draft Date: 26 April 2011
Next Planned Update: 26 April 2016 ESP Transformers - Outdoors

1 Scope

This Specification defines the mandatory requirements for outdoor transformers serving
Electrical Submersible Pump (ESP) systems in crude oil service.

This specification is not applicable to transformers that are integral to AFDs.

2 Conflicts and Deviations

2.1 If there are any conflicts between this specification and associated purchasing,
project or engineering documents, this specification shall take precedence.

2.2 Direct all requests to deviate from this specification in writing to the Company
or Buyer Representative, who shall follow internal company waiver procedure.

2.3 The designation “Commentary” is used to label a sub-paragraph that contains

comments that are explanatory or advisory. These comments are not mandatory,
except to the extent that they explain mandatory requirements contained in this
specification.

3 References

The following is a summary of all the documents which have been mentioned within
this specification. Full compliance to these documents is not necessarily required.
Whether the entire document or specific part(s) of these documents are applicable have
been identified throughout this specification.

 Industry Codes and Standards

American National Standards Institute

ANSI/NFPA 70 National Electrical Code
ANSI C57.12.80 IEEE Standard Terminology for Power and
Distribution Transformers

American Society for Testing and Materials

ASTM D3487 Standard Specification for Mineral Insulating Oil
Used in Electrical Apparatus
ASTM A123 Standard Specification for Zinc (Hot-Dip
Galvanized Coatings on Iron and Steel Products

International Code Council (ICC)

ICC IBC International Building Code

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Document Responsibility: Electric Submersible Pump Standards Committee 55-SAMSS-003
Draft Date: 26 April 2011
Next Planned Update: 26 April 2016 ESP Transformers - Outdoors

International Electrotechnical Committee

IEC 60529 Degrees of Protection Provided by Enclosures
IEC 60296 Fluids for Electrotechnical Applications

National Electrical Manufacturers Association

NEMA 250 Enclosures for Electrical Equipment

4 Definitions

AFD: Adjustable Frequency Drive.

Severely Corrosive Environment: Offshore, or onshore within 5 km of coastline.

Mildly Corrosive Enviroment: Anywhere beyond the 5 km of the coastline.

Crude Oil Service: Directly producing crude oil or producing water in support of
crude oil production.

ESP: Electric Submersible Pump.

Hot-dip galvanized: Meets the requirements of ASTM A123.

MCCB: Molded Case Circuit Breaker.

Main circuit: All the conductive parts of an assembly included in a circuit which is
intended to transfer electrical energy to the connected load.

Offshore: Overwater.

Onshore: On-land.

SD Transformer: Step-down transformer. Transformer used to match the voltage

input of the electrical service to the voltage and phasing requirements of the ESP
controller. This transformer can be dedicated to an individual ESP or can serve
multiple ESPs.

SU Transformer: Step-up transformer. Transformer used to match the voltage output

of the ESP controller to the voltage rating of the ESP motor.

Stainless steel: Either 316 series or 317 series stainless steel material.

Specification: The main body of this document. Does not include the information
contained within the Appendices.

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Document Responsibility: Electric Submersible Pump Standards Committee 55-SAMSS-003
Draft Date: 26 April 2011
Next Planned Update: 26 April 2016 ESP Transformers - Outdoors

5 General

5.1 Words in bold font are defined in Section 4.

5.2 Whenever this specification requires compliance to a third party document

(e.g., API, UL, IEC, etc.), this document shall be the edition which was in effect
on the date of the Quotation Request.

5.3 This specification shall take precedence over any referenced third party
document.

5.4 All documentation shall be in English.

5.5 All temperatures are in Celsius units (unless specified otherwise).

5.6 The specific location(s) and environment in which the transformers will be
installed shall be specified within the purchasing documents.

6 Service Conditions

The transformers shall be designed to operate continuously under the following

conditions:

6.1 Ambient air temperature:

6.1.1 Minimum: 0 degrees.

6.1.2 Maximum: Onshore: 45 degrees, Offshore: 45 degrees.

6.1.3 Average, over one month: Onshore: 40 degrees, Offshore : 35 degrees.

6.2 Manufacturer shall consider internal temperature rise of his equipment and
confirm that it will operate under all load conditions in the environments
indicated in Paragraph 6.1.

The temperature of metal surfaces exposed to direct solar radiation can reach
75°C. The interiors of unventilated metal cabinets (exclusive of internal heat-
producing sources) can reach 56°C. The transformer and its accessories,
including cabinets and junction boxes, shall be designed accordingly. Sun
shields shall not be fitted, unless specified.

6.3 Relative humidity (condensing):

6.3.1 24 hour average: 95%.

6.3.2 1 month average: 90%.

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Document Responsibility: Electric Submersible Pump Standards Committee 55-SAMSS-003
Draft Date: 26 April 2011
Next Planned Update: 26 April 2016 ESP Transformers - Outdoors

6.3.3 Maximum: 100%.

6.4 Earthquakes: None. Site Class D per IBC or ASCE 7.

6.5 Electrical Area Classification: Unclassified.

6.6 Sand and dust storms, fog, airborne contaminants:

6.6.1 NaCl to 300 ppm. MgCl to 50 ppm.

6.6.2 Dust concentrations of 1 mg/m3. 95% of dust particles are less than
20 micrometers in diameter. 50% of dust particles are less than
1.5 micrometers in diameter. Compound in dust include sodium,
magnesium, silicon and aluminum.

6.6.3 Pollutants (worst case): H2S-5 ppm, SO2-10 ppm, CO-100 ppm,
NOx-5 ppm and hydrocarbons-150 ppm.

6.6.4 For offshore installations, accumulation of wetted salt (NaCl) and

windbourne seawater salt spray.

6.7 Wind – maximum:

6.7.1 Two second gust: 32.6 m/sec (73 mph)

6.7.2 One minute withstand: 28.3 m/sec (63 mph).

6.8 Rain: Minimal. Occasional heavy rainstorms.

6.9 Directly exposed to sun.

Exception to 6.9:

Unless indicated otherwise in purchasing documents.

6.10 Altitude: Less than 1000 meters.

6.11 Corrosive Environment.

Exception to 6.11:

Unless indicated otherwise in purchasing documents.

7 Rating

7.1 Transformer nameplate kilo-volt ampere and voltage rating shall be as indicated
on purchasing documents.

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Document Responsibility: Electric Submersible Pump Standards Committee 55-SAMSS-003
Draft Date: 26 April 2011
Next Planned Update: 26 April 2016 ESP Transformers - Outdoors

7.2 The transformers shall be designed to operate continuously at their nameplate

rating in the above service conditions.

8 Construction

8.1 General

8.1.1 Transformers shall be self-cooled, outdoor type.

8.1.2 All current carrying parts shall be copper.

8.1.3 Adhesives shall not be used to control, restrict or prevent movement

(e.g., attachment of nameplates, wire straps, wireways, gaskets, etc.) and
shall not be used to maintain a seal (e.g., interconnection of gasket
surfaces).

8.1.4 Continuous, molded, replaceable gaskets shall be provided on all hinged

doors and externally removable panels. As indicated above, attachment
of the gasket, or integrity of the seal, shall not be dependent upon
adhesives.

8.1.5 All main circuit terminations shall be tin or silver plated.

8.1.6 For a severely corrosive environment, stainless steel hardware shall be

used for the assembly of the complete transformer and skid and for the
attachment of any accessories.

8.1.7 If the transformer assembly is mounted on a skid, the skid shall have the
following characteristics:

8.1.7.1 Steel design shall be in accordance with the AISC, “Manual of

Steel Construction” requirements.

8.1.7.2 Welding shall be in accordance with AWS D1.1 “Structural

Welding Code” requirements. A continuous fillet weld shall be
used to seal all adjoining members.

8.1.7.3 Skid shall be designed to resist, without damage to associated

equipment, all loads and stresses resulting from lifting and
handling. Maximum deflection of the base during lifting and
transporting shall not exceed L/240.

8.1.7.4 If a severely corrosive environment, steel shall be hot-dip

galvanized after the completion of the welding and drilling
associated with the fabrication of the skid structure. It is
acceptable to drill holes in the galvanized skid structure to

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Document Responsibility: Electric Submersible Pump Standards Committee 55-SAMSS-003
Draft Date: 26 April 2011
Next Planned Update: 26 April 2016 ESP Transformers - Outdoors

attach small accessories (e.g., cable clamps) provided the bare

metal is touched-up with zinc-rich paint.

8.1.7.5 Jacking facilities shall be provided for base leveling.

8.1.7.6 Two ground pads shall be welded to the skid at diagonally-

opposed corners. Each pad shall have drilled hole for the
Buyer field connection of a grounding lug with a ½ inch bolt.

8.1.7.7 Shall include integral drip tray(s) with a capacity of 1.5 times
the volume of the transformer oil contained in the
transformer(s) mounted on the skid. If a severely corrosive
environment, drip tray material shall be stainless steel.

8.1.8 Where dissimilar metals are in contact, the contact points shall be
suitably protected to prevent corrosion due to galvanic action.

8.2 Windings

8.2.1 Shall be copper.

8.2.2 Primary windings of SD transformers shall be delta connected.

Exception to 8.2.2:

Wye connection is acceptable for SD transformers with primary

windings rated above 33 kV.

8.3 Tank/Terminal Boxes

8.3.1 Tank covers shall be either bolted or welded.

8.3.2 All welds shall be continuous. Use of tack welds is prohibited.

8.3.3 A sealed-tank design shall be provided as defined by ANSI C57.12.80.

8.3.4 Removable covers into the main tank or terminal boxes shall be gasketed
and bolted with steel bolts. Gaskets shall be neoprene or equivalent.

8.3.5 A pressure/vacuum relief device shall be provided.

8.3.6 Tank and terminal box covers weighing over 10kG shall be provided
with lifting lugs or handles.

8.3.7 Main circuit power terminations shall be provided with bushings

enclosed in an air filled termination box.

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Document Responsibility: Electric Submersible Pump Standards Committee 55-SAMSS-003
Draft Date: 26 April 2011
Next Planned Update: 26 April 2016 ESP Transformers - Outdoors

8.3.8 If a severely corrosive environment, complete tank/terminal boxes and

all accessories and hardware shall be stainless steel.

8.4 Cooling System

8.4.1 Radiators shall be attached to the transformer tank with a bolted flange
and valve set to enable replacement of the radiators without cutting or
welding, and while the transformer is energized.

8.4.2 If a severely corrosive environment, radiators and associated valves,

flanges, accessories and attachment hardware shall be stainless steel.

8.4.3 Consideration shall be given to the thermal conductivity of the radiator

material when determining continuous operational rating of the
transformer service conditions as defined in Section 7.

8.5 Tap Changer

8.5.1 Shall be externally, manually operated rated for de-energized operation.

8.5.2 Shall be oil immersed or hermetically sealed.

8.5.3 Shall be capable of being pad lockable in each position.

8.5.4 Shall have positive visual and tactile position indication.

8.5.5 Shall be designed so that it is not possible to position the tap changer
between taps.

8.5.6 If oil immersed, the tap changer shaft gasket shall be changeable from
outside the tank.

8.5.7 For SD Transformers, shall have the following additional characteristics:

8.5.7.1 A minimum of six(6) taps shall be provided on the high voltage

side of the transformer; four(4) to decrease and two(2) to
increase the transformation ratio.

8.5.7.2 Voltage variance between tap positions shall be approximately

2.5%.

8.5.8 For SU Transformers, shall have the following additional characteristics:

8.5.8.1 A minimum of forty eight (48) different voltages shall be

selectable at the load side of the transformer. This shall be
implemented by a minimum of twenty four (24) tap positions.

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Document Responsibility: Electric Submersible Pump Standards Committee 55-SAMSS-003
Draft Date: 26 April 2011
Next Planned Update: 26 April 2016 ESP Transformers - Outdoors

8.5.8.2 Voltage range shall be specified in the purchasing documents.

8.5.8.3 Manual reconfiguration of the load side transformer winding

connection, in combination with the tap settings, is an
acceptable method of achieving the above voltage levels.

8.6 Loop-Feed Switches

For SD transformers that have been specified with loop-feed switches, these
switches shall be integrated into the transformer or transformer skid assembly.
These switches shall provide open loop feed and isolation functions and shall
have the following characteristics:

8.6.1 Accommodate two (2) cable feeds. Only one of the two cables will be
delivering power.

8.6.2 Switch configuration shall allow the following functions to be performed:

8.6.2.1 Transformer shall be capable of being energized:

8.6.2.1.1 From either cable, while the other cable is isolated

at the transformer.

8.6.2.1.2 When both cables are connected together at the

transformer.

8.6.2.2 Transformer shall be capable of being isolated:

8.6.2.2.1 With either cable energized at the transformer, but

the cables not connected together,

8.6.2.2.2 With the cables connected together (feeding-

through) and energized.

8.6.3 Switches shall be oil immersed or hermetically sealed.

8.6.4 Switch operating mechanism shall be manually charged, stored energy,

quick-make/quick-break type in which open and close operations are
independent of operating handle speed.

8.6.5 Switch shall be load-break and have a minimum continuous current and
load-break rating of 200 amps.

8.6.6 Current-limiting fuses shall be installed to protect each transformer.

The fuses shall be sized by the transformer manufacturer and be
replaceable without opening the transformer tank.

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Document Responsibility: Electric Submersible Pump Standards Committee 55-SAMSS-003
Draft Date: 26 April 2011
Next Planned Update: 26 April 2016 ESP Transformers - Outdoors

8.6.7 If installed in a severely corrosive environment, complete external

switch assembly including accessories and attachment hardware shall be
stainless steel.

8.7 Distribution Panel

If the SD transformer feeds multiple ESP controllers, a distribution panel shall

be integrated into the transformer or transformer skid assembly. This
distribution panel shall have the following characteristics:

8.7.1 Contain a manually operable MCCB for each three (3) phase circuit.

8.7.2 MCCBs feeding an individual ESP controller should be grouped together.

8.7.3 MCCBs shall have provisions for padlocking in the open position.

8.7.4 MCCBs should be oriented so that operating handle OFF position is on

the bottom or the left.

8.7.5 Shall be constructed per the requirements in Section 8.8.

8.7.6 Hinged doors shall be provided.

8.7.7 If a severely corrosive environment, complete panel and all associated

accessories and hardware, shall be stainless steel.

8.8 Enclosures

8.8.1 The transformer terminal boxes, distribution panel enclosure and

auxiliary transformer enclosures shall have the following characteristics:

8.8.1.1 Be equipped with either:

8.8.1.1.1 A breather and drain mechanism.

8.8.1.1.2 A 5mm hole drilled in the bottom of the enclosure.

8.8.1.2 If installed in a severely corrosive environment:

8.8.1.2.1 Meet the equivalent performance requirements of a

NEMA 250 Type 4X (stainless steel) or IP6X per
IEC 60529 with „X‟ being a numeral between „4‟
and „8‟.

8.8.1.2.2 Box material and external hardware such as

fasteners (bolts, screws), hinges and locking devices
shall be stainless steel.

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Document Responsibility: Electric Submersible Pump Standards Committee 55-SAMSS-003
Draft Date: 26 April 2011
Next Planned Update: 26 April 2016 ESP Transformers - Outdoors

8.8.1.3 If installed in a mildly corrosive environment:

8.8.1.3.1 Meet the equivalent performance requirements of a

NEMA 250 Type 4 or IP6X per IEC 60529 with „X‟
being a numeral between „4‟ and „8‟.

8.8.1.3.2 Box material shall be Manufacturer‟s standard and

external hardware such as fasteners (bolts, crews),
hinges and locking devices shall be of similar metal
to the enclosure to avoid galvanic corrosion.

8.8.1.4 Shall be designed for bottom entry of the cables. Cable

number, size and type shall be as indicated in the purchasing
documents.

8.8.2 Hinged doors shall have the following characteristics:

8.8.2.1 Shall be equipped with captive hardware.

8.8.2.2 Shall be electrically bonded to the stationary enclosure.

8.8.2.3 Each hinged door unit shall be a maximum of 900 mm wide.

8.9 Insulation Oil

8.9.1 Transformers shall be shipped filled with insulating oil. Insulating oil
shall have the following characteristics:

8.9.1.1 The oil shall be virgin mineral oil specifically manufactured for
use as electrical insulating oil.

8.9.1.2 The oil shall contain no additives and shall meet IEC 60296
Class 1 or ASTM D3487 Type 1.

8.9.1.3 The transformers shall be supplied with labels indicating that

they are PCB free

8.9.2 Oil filled transformers shall be shipped with the tank pressurized with a
blanket of dry nitrogen.

8.10 Wireways/Raceways

Wireways and raceways shall be either hot-dip galvanized or stainless steel.

Exception to 8.10:

Flexible conduit; if liquid tight non-metallic overall sheath is used.

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Document Responsibility: Electric Submersible Pump Standards Committee 55-SAMSS-003
Draft Date: 26 April 2011
Next Planned Update: 26 April 2016 ESP Transformers - Outdoors

8.11 Conductors/Cables

All cables shall have a liquid tight non-metallic overall sheath.

8.12 Painting/Coatings

Hot-dip galvanized and stainless steel surfaces shall not be painted or coated.

8.13 Accessories

Transformer shall be equipped with the following accessories:

8.13.1 Drain and sampling valves.

8.13.2 Liquid level gauge.

8.13.3 Two ground pads at diagonal corners drilled for ½ inch bolts.

8.13.4 Top-mounted dial type oil temperature indicator with re-settable

maximum pointer.

8.13.5 Pressure indicating device for internal tank pressure.

8.13.6 Pressure relief device, automatic reset type with indicator.

8.13.7 Provision for jacking.

8.13.8 Lifting lugs for lifting complete transformer.

8.13.9 Pressure test connection.

8.14 Nameplates

Each piece of equipment shall have an embossed stainless steel nameplate

securely fastened with stainless steel screws or rivets showing the following
minimum information:
8.14.1 Purchase order number.
8.14.2 KVA rating OA/FA, 45 /65C.
8.14.3 Volts at no-load and at each tap position for high voltage.
8.14.4 Volts at no-load for low voltage.
8.14.5 Current at rated load and normal tap for high voltage.
8.14.6 Current at rated load and normal tap for low voltage.

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Document Responsibility: Electric Submersible Pump Standards Committee 55-SAMSS-003
Draft Date: 26 April 2011
Next Planned Update: 26 April 2016 ESP Transformers - Outdoors

8.14.7 Number of phases.

8.14.8 Frequency.
8.14.9 Impedance at normal tap.
8.14.10 Vector group reference.
8.14.11 Tap arrangement.
8.14.12 Quantity of oil in U.S. – gallons.
8.14.13 Weight of oil in pounds.
8.14.14 Weight of core and winding assembly in pounds.
8.14.15 Total weight in pounds.
8.14.16 Manufacturer‟s serial number.
8.14.17 Year of manufacture.

9 Testing

9.1 Each transformer shall undergo the following tests:

9.1.1 Winding resistance.
9.1.2 Turns ratio.
9.1.3 Polarity and phase relationship.
9.1.4 No load losses and excitation current.
9.1.5 Impedance voltage.
9.1.6 Dielectric (induced potential).
9.1.7 Leak test.

9.2 Test shall be documented in a certified report that is provided with the
transformer.

10 Shipping

10.1 Transformer or transformer skid assembly shall be designed to be transported to,

and installed at the site as one complete unit without requiring field assembly.

10.2 As indicated above, oil filled transformers shall be shipped filled with oil.

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Document Responsibility: Electric Submersible Pump Standards Committee 55-SAMSS-003
Draft Date: 26 April 2011
Next Planned Update: 26 April 2016 ESP Transformers - Outdoors

Revision Summary
26 April 2011 New Saudi Aramco Materials System Specification.

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